Superjunction semiconductor device with columnar region under base layer and manufacturing method therefor

ABSTRACT

A semiconductor device that includes the following is manufactured: an n −  base layer; a p-type base layer formed on the surface of the n −  base layer; an n +  source layer formed in the inner area of the p-type base layer; a gate electrode formed so as to face a channel region across a gate insulating film; a plurality of p-type columnar regions that are formed in the n −  base layer so as to continue from the p-type base layer and that are arranged at a first pitch; and a plurality of p +  collector layers that are selectively formed on the rear surface of the n −  base layer and that are arranged at a second pitch larger than the first pitch.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a superjunction semiconductor device.

2. Description of Related Art

It is well-known that IGBTs (insulated gate bipolar transistors) areused as switching devices in inverter circuits or power circuitsprovided in various types of home appliances such as refrigerators,air-conditioners, and laundry machines; energy-related systems such assolar power generating systems and wind power generating systems; andvehicles such as electric vehicles (EV) and hybrid electric vehicles(HEV), for example.

An IGBT disclosed in Patent Document 1 includes: an n⁻ drift layer; ap-type base layer formed on the n⁻ drift layer; an n⁺ emitter layerformed on a portion of the surface of the p-base layer; a trench formedso as to penetrate the n⁺ emitter layer; a gate electrode formed in thetrench across a gate insulating film; an n-buffer layer formed on thebottom of the wafer; a p-collector layer formed further towards thebottom of the wafer than the n-buffer layer; an emitter electrode formedon the top of the wafer; and a collector electrode formed on the bottomof the wafer.

Patent Document 1: Japanese Patent No. 5036327

In the set shown as an example above, there has been demand for moreenergy savings for all embedded applications in order to reduce theimpact on the environment. The IGBT switching device, however, differsfrom a MOSFET in that the IGBT is a bipolar device, and thus, an ONvoltage greater than or equal to the VF (forward voltage) to the currentis necessary. As a result, if using IGBTs in a motor driving circuit,for example, the efficiency of the set using this motor driving circuitwill be low in low voltage ranges.

On the other hand, the MOSFET, which is a unipolar device, can form aset with excellent efficiency in low voltage ranges as compared to theIGBT if used in the above-mentioned set, and therefore, is used insteadof the IGBT. In general, however, the chip size of the MOSFET must bemade larger in order to be compatible with both low voltage ranges andhigh voltage ranges, which leads to an increase in cost.

The MOSFETs that are used as switching devices in inverter circuits andpower circuits are largely separated into planar types and superjunctiontypes. Planar MOSFETs include a drain layer, an n-type base layerarranged on this drain layer, a p-type base layer formed on the surfaceof the n-type base layer, and an n⁺ drain layer and n⁺ source layerformed on the surface of the p-type base layer with a gap therebetween,for example. The gate electrode is arranged so as to face the surface ofthe p-type base layer between the n⁺ source/drain layer across the gateinsulating film.

As disclosed in Patent Document 2, superjunction MOSFETs include ap-type columnar region that extends from the p-type base layer towardsthe drain layer, in addition to the configuration of the planar MOSFETdescribed above, for example. This structure enables a reduction inon-resistance and improves switching speed.

Patent Document 2: Japanese Patent Application Laid-Open Publication No.2012-142330

One problem with superjunction MOSFETs is the hard recovery of theparasitic diode. Hard recovery means that the change in reverse recoverycurrent (dir/dt) is fast. In superjunction MOSFETs, a depletion layerspreads from both the p-type base layer and the p-type columnar regionwhen the parasitic diode is turned off. In particular, the depletionlayer that spreads from the p-type columnar region quickly bonds withthe depletion layer that spreads from another adjacent p-type columnarregion and quickly reaches the drain layer directly below. Therefore,the current changes rapidly, and blocking of the reverse recoverycurrent also occurs at a high speed. In response to this, the reverserecovery current waveforms exhibit an oscillation (ringing) with steepchanges and a large amplitude. Such reverse recovery characteristics(hard recovery characteristics) cause a large amount of noise, and couldcause the controller supplying control signals to the MOSFETs tomalfunction, for example. In particular, in an inverter circuit thatdrives an inductive load such as in an electric motor, the parasiticdiode turns ON and OFF; therefore, the hard recovery characteristicswhen this parasitic diode is turned off poses a problem. According toPatent Document 2 mentioned above, the reverse recovery characteristicsare improved by heavy particle irradiation from the rear surface of then-type drain layer with heavy particles such as protons, ³He⁺⁺, and⁴He⁺⁺, but this does not improve the hard recovery characteristics.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to superjunctionsemiconductor devices and their manufacturing method that substantiallyobviate one or more of the problems due to limitations and disadvantagesof the related art.

An aim of the present invention is to provide an improved and highlyfunctional MOSFET.

An aim of the present invention is to provide a semiconductor device inwhich on-resistance can be evenly reduced in both low voltage ranges andhigh voltage ranges.

An aim of the present invention is to provide a superjunctionsemiconductor device in which it possible to alleviate hard recovery ofa parasitic diode with a simple structure, and a method of manufacturingthis semiconductor device.

Additional or separate features and advantages of the invention will beset forth in the descriptions that follow and in part will be apparentfrom the description, or may be learned by practice of the invention.The objectives and other advantages of the invention will be realizedand attained by the structure particularly pointed out in the writtendescription and claims thereof as well as the appended drawings.

To achieve some or all of these advantages and other advantages inaccordance with the purposes of the present invention, as embodied andbroadly described, the present invention provides a semiconductor devicethat includes: a first conductive type base layer; a plurality of secondconductive type base layers selectively formed on a surface of the firstconductive type base layer; a first conductive type source layer that isformed in an inner area of the respective second conductive type baselayers at a gap from a periphery of the respective second conductivetype base layers, the first conductive type source layer forming achannel region with this periphery; a gate electrode formed so as toface the channel region across a gate insulating film; a plurality ofsecond conductive type columnar regions that are formed in the firstconductive type base layer so as to continue from the respective secondconductive type base layers and that are arranged at a prescribed firstpitch with respect to the second conductive type base layers that areadjacent to each other; and a plurality of second conductive typecollector layers that are selectively formed on a rear surface of thefirst conductive type base layer and that are arranged at a prescribedsecond pitch, the second pitch being larger than the first pitch of thesecond conductive type columnar regions.

With this configuration, a plurality of the second conductive typecollector layers are selectively formed on the rear surface of the firstconductive type base layer; therefore, both the first conductive typebase layer and the second conductive type collector layers are exposedon this rear surface. This makes it possible, when used in a set, toprovide a semiconductor device that has MOSFET characteristics capableof forming a set with excellent efficiency in low voltage ranges andIGBT characteristics capable of generating conductivity modulation inhigh voltage ranges due to the rear surface electrode being formed so asto contact the first conductive type base layer and the secondconductive type collector layers exposed on the rear surface of thefirst conductive type base layer.

Meanwhile, the respective occupancies of the first conductive type baselayer and the second conductive type collector layers with respect tothe entire rear surface of the first conductive type base layer aresmaller than regular MOSFETs and IGBTs where the entire rear surface isoccupied by a single first conductive type area or second conductivetype area. Thus, if the area of either the first conductive type baselayer or the second conductive type collector layers is increased, thearea of the other will decrease. As a result, the contact resistance ofthe rear surface electrode to the relatively small layer is increased,and the reducing effect of the on-resistance is weakened. In otherwords, there is a trade-off between the MOSFET characteristics and theIGBT characteristics given to the semiconductor device.

After earnest and diligent research, the inventors of the presentinvention were able to evenly reduce the on-resistance in low voltageranges and high voltage ranges, not by matching the pitch of the secondconductive type collector layers to the pitch of the second conductivetype columnar regions (first pitch=second pitch), but by making thesecond pitch larger than the first pitch (second pitch>first pitch). Asa result, the semiconductor device of this aspect of the presentinvention can have optimal device characteristics for a variety ofapplications.

In one embodiment, it is preferable that the second pitch be two timesto five times the first pitch.

In one embodiment, it is preferable that the occupancy of the secondconductive type collector layer with respect to the entire rear surfaceof the first conductive type base layer be 40% to 80%.

In one embodiment, the second conductive type collector layers may beformed so as to face the respective second conductive type columnarregions in a thickness direction of the first conductive type baselayer. With this configuration, on-resistance can be greatly reduced inhigh voltage ranges.

In one embodiment, the second conductive type columnar regions may beformed in a stripe shape in a plan view. In this case, in oneembodiment, it is preferable that the second conductive type collectorlayers be formed in a shape that intersects the respective secondconductive type columnar regions and that faces the respective secondconductive type columnar regions at this intersection in a plan view. Inone embodiment, it is preferable that the second conductive typecollector layers be formed in a stripe shape in a plan view. In oneembodiment, it is preferable that the second conductive type collectorlayers be formed in a stripe shape that is orthogonal to the respectivesecond conductive type columnar regions in a plan view. In oneembodiment, if the second conductive type collector layers are formed ina stripe shape that intersects the respective second conductive typecolumnar regions in a plan view, then the second conductive typecollector layers may be formed in a polygonal shape or a circular shapein a plan view.

In other words, if each of the second conductive type collector layersrespectively faces one of the second conductive type column sectionsaligned in a stripe shape, then variation in on-resistance between thecells of the semiconductor device will be reduced. In one embodiment,second conductive type collector layers may be formed in stripe shapesthat intersect second conductive type columnar regions, the respectivesecond conductive type collector layers may continue across a pluralityof the second conductive type columnar regions, and may approximatelyevenly face all of the respective second conductive columnar regions.Similarly, in one embodiment, second conductive type collector layersmay be formed in stripe shapes that are orthogonal to second conductivetype columnar regions, and a uniform amount of the second conductivecollector layers may be made to reliably face all of the respectivesecond conductive type columnar regions.

In one embodiment, the second conductive type collector layers may beformed in a stripe shape that is parallel to the respective secondconductive type columnar regions in a plan view.

In one embodiment, the second conductive type columnar regions may beformed in a polygonal shape or a circular shape. In this case, thesecond conductive type collector layers may be formed in a stripe shapein a plan view from a direction normal to the surface of the firstconductive type base layer, or may be formed in a polygonal shape or acircular shape in a plan view from a direction normal to the surface ofthe first conductive type base layer.

In one embodiment, the first conductive type base layer may include afirst conductive type contact layer arranged between each of theplurality of the second conductive type collector layers, the firstconductive type base layer having a higher impurity concentration than afirst conductive type drift layer that is formed in a top area of theplurality of the second conductive type collector layers. With thisconfiguration, the rear surface electrode can be made to have afavorable+ohmic connection with the first conductive type base layer.

In one embodiment, it is preferable that a ratio of a width of thesecond conductive type collector layer to a width of the firstconductive type contact layer in each second pitch be 1:1.

In one embodiment, it is preferable that the first pitch be 5 μm to 20μm and the second pitch be 5 μm to 200 μm.

In one embodiment, it is preferable that the second conductive typecollector layers have a width of 2.5 μm to 160 μm.

In one embodiment, it is preferable that the second conductive typecollector layers have a depth of 0.2 μm to 3.0 μm from the rear surfaceof the first conductive type base layer.

In one embodiment, it is preferable that the second conductive typecollector layers have an impurity concentration of 1×10¹⁷ cm⁻³ to 1×10²²cm⁻³.

In a second aspect of the present invention, the present inventionprovides a semiconductor device that includes: a first conductive typedrain layer; a first conductive type base layer formed on the firstconductive type drain layer; a plurality of second conductive type baselayers selectively formed on a surface of the first conductive type baselayer; a first conductive type source layer that is formed in an innerarea of the respective second conductive type base layers at a gap froma periphery of the respective second conductive type base layers, thefirst conductive type source layer forming a channel region with thisperiphery; a gate electrode formed so as to face the channel regionacross a gate insulating film; a second conductive type columnar regionthat is formed in the first conductive type base layer and that extendstowards the first conductive type drain layer from at least some of thesecond conductive type base layers; a drain electrode electricallyconnected to the first conductive type drain layer; and a sourceelectrode electrically connected to the first conductive type sourcelayer, wherein the second conductive type columnar region has a topcolumnar region integrally formed with the respective second conductivetype base layers and a bottom columnar region that is longer than thetop columnar region and that is electrically floating.

The semiconductor device of this aspect of the present invention forms asuperjunction MOSFET by the second conductive type columnar regions thatcontinue from the second conductive type base layer extending towardsthe first conductive type drain layer. If the first conductive type isn, and the second conductive type is p, then an inversion layer(channel) will be formed in the channel region near the surface of thep-type base layer if the drain electrode connects to a higher potentialthan the source electrode and a control voltage above the thresholdvoltage is applied to the gate electrode. This forms a current path thatpasses through the drain electrode, n-type drain layer, n-type baselayer, the inversion layer of the p-type base layer surface, the n-typesource layer, and the source electrode in this order. If a controlvoltage is not applied to the gate electrode, then the inversion layerwill not be formed, and the current path will be blocked. The p-njunction between the p-type base layer and the p-type top columnarregion integrated therewith and the n-type base layer forms a parasiticdiode. This parasitic diode is in an ON-state when forward voltage isapplied, and is in an off-state when reverse voltage is applied. Whenthe parasitic diode is turned OFF, reverse recovery occurs in which thecarriers (holes) in the p-type base layer and the top columnar regionare attracted to the source electrode and the carriers (electrons) inthe n-type base layer and the n-type drain layer are attracted to thedrain electrode. The current that flows due to this phenomenon is thereverse recovery current. The depletion layer spreads from the p-njunction and the parasitic diode turns OFF due to the movement of thecarriers.

In this example of the present aspect, the p-type columnar regions arerespectively separated into top and bottom, and the relatively longbottom columnar regions are electrically floating with respect to thep-type base layer. Accordingly, the operation of the parasitic diodedoes not contribute to the bottom columnar region, thus suppressingrapid spreading of the depletion layer during reverse recovery. Thissuppresses the spread of the depletion layer towards the drainelectrode, thereby suppressing the speed at which the depletion layerspreads when the parasitic diode is turned OFF. This reduces the speedof change of the reverse recovery current (dir/dt), and thus improvesthe recovery characteristics. The structure is also simple, as theseparated columnar region simply needs to be provided.

Furthermore, although the columnar regions are separated, in the presentexample the configuration has a superjunction structure in which thep-type columnar regions extend from the p-type base layer towards the n⁺drain layer. Accordingly, by determining the shape of the top columnarregion and the bottom columnar region and the gap therebetween such thatthe respective depletion layers spreading laterally from the topcolumnar region and the bottom columnar region merge together, it ispossible to achieve the inherent superjunction characteristics offavorable on-resistance and switching speed.

The above-mentioned effects are also attainable if the first conductivetype is n and the second conductive type is p.

In one embodiment of the invention of the present aspect, thesemiconductor device may further include a second conductive typeauxiliary area formed at a location that is laterally separated with agap from both the top columnar region and the bottom columnar region.

With this configuration, the respective depletion layers spreadinglaterally from the top columnar regions and the bottom columnar regionscan be relayed by the depletion layers spreading from the assist regionsof the second conductive type; therefore, the second conductive typeassist regions can assist in the merging of the depletion layers.

In one embodiment, it is preferable that the top columnar region and thebottom columnar region are separated by a gap that is less than or equalto 10 μm in a vertical direction. With this configuration, it ispossible to make it easy to merge together the respective depletionlayers spreading in the lateral direction from the top columnar regionand the bottom columnar region.

In one embodiment, at least some of the second conductive type baselayers may selectively have a continuous columnar region that continuesfrom the respective second conductive type base layers to a bottom edgeof the bottom columnar region. With this configuration, by selectivelyproviding the continuous column sections that are specialized forsuperjunction characteristics, it is possible to adjust the trade-offbetween the switching speed and on-resistance of the semiconductordevice.

In one embodiment, the semiconductor device of the second aspect mayinclude a second conductive type collector layer partially formed on arear surface of the first conductive type.

With this configuration, electrons or holes are implanted into the firstconductive type base layer from the second conductive type collectorlayers; therefore, conductivity modulation can be performed in the firstconductive type base layer. As a result, in high voltage ranges, thecurrent can be elevated along the current waveform depicted duringoperation of the IGBT. In other words, when used in a set, it ispossible to provide a semiconductor device that has MOSFETcharacteristics capable of forming a set with excellent efficiency inlow voltage ranges and IGBT characteristics capable of generatingconductivity modulation in high voltage ranges. Furthermore, thesemiconductor device has the columns that are the second conductive typecolumnar regions separated into top and bottom, thus making it possibleto favorably reduce ON-resistance in high voltage ranges as compared toif second conductive type collector layers were provided in asemiconductor device in which all of the second type columnar regionsare continuous columnar regions.

In one embodiment, the second conductive type columnar region may bearranged at a prescribed first pitch between the second conductive typebase layers that are adjacent, and the second conductive type collectorlayer may be arranged at a prescribed second pitch larger than the firstpitch of the second conductive type columnar region.

The respective areas taken up by the first conductive type drain layerand the second conductive type collector layers with respect to theentire rear surface of the first conductive type drain layer are smallerthan in regular MOSFETs and IGBTs in which the entire rear surface isoccupied by a single first conductive type area or second conductivetype area, for example. Thus, if the area of either the first conductivetype drain layer or the second conductive type collector layers isincreased, the area of the other will decrease. As a result, the contactresistance of the drain electrode with respect to the relatively narrowlayer will increase, and this will weaken the reducing effect of theON-resistance. In other words, there is a trade-off between the MOSFETcharacteristics and the IGBT characteristics given to the semiconductordevice.

After earnest and diligent research, the inventor of the presentinvention was able to evenly reduce the on-resistance in low voltageranges and high voltage ranges, not by matching the pitch of the secondconductive type collector layers to the pitch of the second conductivetype column sections (first pitch=second pitch), but by making thesecond pitch larger than the first pitch (second pitch>first pitch). Asa result, this semiconductor device can have optimal devicecharacteristics for a variety of applications.

In one embodiment, it is preferable that the second pitch be two timesto five times the first pitch.

In one embodiment, it is preferable that the occupancy of the secondconductive type collector layer with respect to the entire rear surfaceof the first conductive type drain layer be 40% to 80%.

In one embodiment, the second conductive type collector layers may beformed so as to face the respective second conductive type columnarregions in a thickness direction of the first conductive type baselayer. With this configuration, on-resistance can be greatly reduced inhigh voltage ranges.

In one embodiment, the second conductive type columnar regions may beformed in a stripe shape in a plan view. In this case, in oneembodiment, it is preferable that the second conductive type collectorlayers be formed in a shape that intersects the respective secondconductive type columnar regions and that faces the respective secondconductive type columnar regions at this intersection in a plan view. Inone embodiment, it is even more preferable that the second conductivetype collector layers be formed in a stripe shape in a plan view, and inone embodiment, it is particularly preferable that that the secondconductive type collector layers be formed in a stripe shape that isorthogonal to the respective second conductive columnar regions in aplan view. If the second conductive type collector layers are formed ina stripe shape that intersects the respective stripe-shaped secondconductive type columnar regions in a plan view, then the secondconductive type collector layers may be formed in a polygonal shape or acircular shape in a plan view.

In one embodiment, in other words, if each of the second conductive typecollector layers respectively faces one of the second conductive typecolumn sections aligned in a stripe shape, then variation inon-resistance between the cells of the semiconductor device will bereduced. In one embodiment, the second conductive type collector layersmay be formed in stripe shapes that intersect the second conductive typecolumnar regions, the respective second type conductive collector layersmay continue across a plurality of the second conductive type columnarregions, and may approximately evenly face all of the respective secondconductive columnar regions. Similarly, in one embodiment, secondconductive type collector layers may be formed in stripe shapes that areorthogonal to second conductive type columnar regions, and a uniformamount of the second conductive collector layers may be made to reliablyface all of the respective second conductive type columnar regions.

In one embodiment, the second conductive type collector layers may beformed in a stripe shape that is parallel to the respective secondconductive type columnar regions in a plan view.

In one embodiment, the second conductive type columnar regions may beformed in a polygonal shape or a circular shape in a plan view.

In this case, in one embodiment, the second conductive type collectorlayers may be formed in a stripe shape in a plan view, and in oneembodiment, may be formed in a polygonal or a circular shape in a planview.

In one embodiment, it is preferable that a ratio of a width of thesecond conductive type collector layer to a width of the firstconductive type drain layer in each second pitch be 1:1.

In one embodiment, it is preferable that the first pitch be 5 μm to 20μm and that the second pitch be 5 μm to 200 μm.

In one embodiment, it is preferable that the second conductive typecollector layers have a width of 2.5 μm to 160 μm.

According to a third aspect of the present invention, the presentinvention provides a method of manufacturing a semiconductor device,including: forming a first conductive type base layer on a firstconductive type drain layer by selectively implanting a secondconductive type impurity into a prescribed first horizontal location andthen forming a bottom main layer that is of a first conductive typethrough epitaxial growth for a first period of time in locations otherthan this prescribed first horizontal location, thereafter forming afirst conductive type sub-layer through epitaxial growth on the entiretyof this bottom main layer, and then forming a top main layer thereonhaving the same structure as the bottom main layer through epitaxialgrowth for a second period of time that is shorter than the first periodof time; forming a second conductive type columnar region by annealingthe first conductive type base layer having the top main layer and thebottom main layer and then diffusing the second conductive type impurityinside the top main layer and the bottom main layer, the secondconductive type columnar region having a top columnar region verticallyseparated by the sub-layer and a bottom columnar region that is longerthan the top columnar region; selectively forming a second conductivetype base layer on the surface of the first conductive type base layer,the second conductive type base layer continuing from the secondconductive type columnar region; forming a first conductive type sourcelayer on an inner area of the second conductive type base layer suchthat a gap is present between a periphery of the second conductive typebase layer and the first conductive type source region, the firstconductive type source layer forming a channel region between thisperiphery and the second conductive type base layer; forming a gateelectrode so as to face the channel region across a gate insulatingfilm; forming a drain electrode that is electrically connected to thefirst conductive type drain layer; and forming a source electrode thatis electrically connected to the first conductive type source layer.

The semiconductor devices described above can be manufactured by thismethod and similar methods, for example.

In one embodiment, the step of forming the first conductive type baselayer may include forming the bottom main layer by epitaxially growing aplurality of layers at a prescribed first thickness, thereafterepitaxially growing a single layer of the sub-layer having the samethickness as the first prescribed thickness, and then forming the topmain layer by again epitaxially growing a plurality of the layers havingthe first prescribed thickness but in a smaller number than the bottommain layer.

With this method, the length of the top columnar region and the bottomcolumnar region can be adjusted with ease by controlling the number ofmain layers formed through epitaxial growth.

In one embodiment, the step of forming the sub-layer through epitaxialgrowth may include forming the sub-layer while implanting the secondconductive type impurity at a second horizontal location that islaterally separated from the first horizontal location, and the step offorming the second conductive type columnar region may include formingthe second conductive type auxiliary area with gaps from both the topcolumnar region and the bottom columnar region by diffusing the secondconductive type impurity inside the sub-layer through the annealingtreatment.

In one embodiment, the step of forming the sub-layer through epitaxialgrowth may include forming a buffer layer of 5 μm to 30 μm.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory, andare intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view of a semiconductor device according toEmbodiment 1 of the present invention.

FIG. 2 is a cross-sectional view along the line II-II in FIG. 1.

FIG. 3A is a view of a portion of a manufacturing process of thesemiconductor device in FIGS. 1 and 2.

FIG. 3B is a view of the next step after the step in FIG. 3A.

FIG. 3C is a view of the next step after the step in FIG. 3B.

FIG. 3D is a view of the next step after the step in FIG. 3C.

FIG. 3E is a view of the next step after the step in FIG. 3D.

FIG. 3F is a view of the next step after the step in FIG. 3E.

FIG. 3G is a view of the next step after the step in FIG. 3F.

FIG. 3H is a view of the next step after the step in FIG. 3G.

FIG. 3I is a view of the next step after the step in FIG. 3H.

FIG. 3J is a view of the next step after the step in FIG. 3I.

FIG. 4 is a modification example of the layout of the p-type columnarregions and p⁺ collector layers.

FIG. 5 is a modification example of the layout of the p-type columnarregions and p⁺ collector layers.

FIG. 6 is a modification example of the layout of the p-type columnarregions and p⁺ collector layers.

FIG. 7 is a modification example of the layout of the p-type columnarregions and p⁺ collector layers.

FIG. 8A is a modification example of a manufacturing step of the p-typecolumnar regions in FIG. 2.

FIG. 8B is a view of the next step after the step in FIG. 8A.

FIG. 8C is a view of the next step after the step in FIG. 8B.

FIG. 8D is a view of the next step after the step in FIG. 8C.

FIG. 9 is a schematic plan view of a semiconductor device according toEmbodiment 2 of the present invention.

FIG. 10A is a view of a part of a manufacturing step of thesemiconductor device in FIG. 9.

FIG. 10B is a view of the next step after the step in FIG. 10A.

FIG. 10C is a view of the next step after the step in FIG. 10B.

FIG. 10D is a view of the next step after the step in FIG. 10C.

FIG. 10E is a view of the next step after the step in FIG. 10D.

FIG. 11 is a schematic cross-sectional view of a semiconductor device ofEmbodiment 3 of the present invention.

FIG. 12A is a view of a portion of a manufacturing process of thesemiconductor device in FIG. 11.

FIG. 12B is a view of the next step after the step in FIG. 12A.

FIG. 12C is a view of the next step after the step in FIG. 12B.

FIG. 12D is a view of the next step after the step in FIG. 12C.

FIG. 12E is a view of the next step after the step in FIG. 12D.

FIG. 12F is a view of the next step after the step in FIG. 12E.

FIG. 13 is a view of a modification example of the gate structure inFIG. 2.

FIG. 14A is a graph that shows the Id-Vd characteristics of thesemiconductor device for each pitch of the p⁺ collector layers.

FIG. 14B is a graph in which the characteristics in the low voltagerange of FIG. 14A have been magnified.

FIG. 15 is a graph that shows variation in ON-resistance between thecells of the semiconductor device for each layout of the p⁺ collectorlayers.

FIG. 16 is a schematic plan view of a semiconductor device of Embodiment4 of the present invention.

FIG. 17 is a cross-sectional view along the line II-II in FIG. 16.

FIG. 18A is a view of a portion of a manufacturing process of thesemiconductor device in FIGS. 16 and 17.

FIG. 18B is a view of the next step after the step in FIG. 18A.

FIG. 18C is a view of the next step after the step in FIG. 18B.

FIG. 19 is a schematic plan view of a semiconductor device of Embodiment5 of the present invention.

FIG. 20 is a cross-sectional view along the line V-V in FIG. 19.

FIG. 21A is a view of a portion of a manufacturing process of thesemiconductor device in FIGS. 19 and 20.

FIG. 21B is a view of the next step after the step in FIG. 21A.

FIG. 21C is a view of the next step after the step in FIG. 21B.

FIG. 21D is a view of the next step after the step in FIG. 21C.

FIG. 21E is a view of the next step after the step in FIG. 21D.

FIG. 21F is a view of the next step after the step in FIG. 21E.

FIG. 21G is a view of the next step after the step in FIG. 21F.

FIG. 22 is a modification example of the layout of the p-type columnarregions and p⁺ collector layers.

FIG. 23 is a modification example of the layout of the p-type columnarregions and p⁺ collector layers.

FIG. 24 is a modification example of the layout of the p-type columnarregions and p⁺ collector layers.

FIG. 25 is a modification example of the layout of the p-type columnarregions and p⁺ collector layers.

FIG. 26 is a schematic cross-sectional view of a semiconductor device ofEmbodiment 6 of the present invention.

FIG. 27 is a waveform diagram of one example of current waveform fromwhen the parasitic diode is in an on-state to when it is turned off.

FIG. 28A is a graph of Id-Vd characteristics of the semiconductordevice.

FIG. 28B is a graph in which the characteristics in the low voltagerange of FIG. 28B have been magnified.

FIG. 29 is a graph of the relationship between drain-source voltage andoutput capacitance of the semiconductor device.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

<Embodiment 1>

Below, embodiments of the present invention will be explained in detailwith reference to appended drawings. FIG. 1 is a schematiccross-sectional view of a semiconductor device 1 according to Embodiment1 of the present invention. FIG. 2 is a cross-sectional view along thecross-section II-II in FIG. 1. In FIG. 1, only the elements necessaryfor explanation are shown, and a gate electrode 7, source electrode 8,and the like, for example, are omitted.

The semiconductor device 1 is a superjunction n-channel MOSFET (metaloxide semiconductor field effect transistor). The semiconductor device 1includes an n⁻ base layer 2, p-type columnar regions 3, p-type baselayers 4, n⁺ source layers 5, gate insulating films 6, gate electrodes7, source electrodes 8, n⁺ contact layers 9, p⁺ collector layers 10, adrain electrode 11, a depletion layer reducing area 30, and a trap levelarea 32. Interlayer insulating films 12 are arranged on the respectivegate electrodes 7.

The n⁻ base layer 2 is a semiconductor layer in which an n-type impurityhas been implanted. More specifically, the n⁻ base layer 2 may be ann-type epitaxial layer that is epitaxially grown while implanting ann-type impurity. P (phosphorous), As (arsenic), SB (antimony) or thelike can be used as the n-type impurity.

The p-type columnar regions 3 and p-type base layers 4 are semiconductorlayers in which a p-type impurity has been implanted. More specifically,the p-type columnar regions 3 and p-type base layers 4 may besemiconductor layers that are respectively formed by the ionimplantation of a p-type impurity in the n⁻ base layer 2. B (boron), Al(aluminum), Ga (gallium), or the like can be used as the p-typeimpurity.

As shown in FIG. 1, the p-type base layers 4 are selectively formed onthe surface of the n⁻ base layer 2 in a plurality of areas that arearranged periodically and apart from each other in a plan view seen froma direction normal to the surface of the n⁻ base layer 2 (hereinafter,referred to simply as “a plan view”). In this embodiment, theseplurality of p-type base layers 4 are formed in mutually parallel stripeshapes. The width of the respective p-type base layers 4 is 3 μm to 10μm, for example. The individual p-type base layers 4 and the areaincluding the n-base layer 2 surrounding these form cells 13. In otherwords, in the layout in FIG. 1, this semiconductor device 1 has a largenumber of cells 13 arrayed in stripe shapes in a plan view.

The p-type columnar regions 3 are formed in the inner area of the p-typebase layer 4 of each of the cells 13 in a plan view. More specifically,in the present embodiment, the p-type columnar regions 3 arerespectively formed in stripe shapes in the center area in the widthwisedirection of the p-type base layers 4. The p-type columnar regions 3 areformed so as to continue from the respective p-type base layers 4, andextend towards the rear of the n− base layer 2 to a position that isdeeper than the p-type base layers 4. Accordingly, the p-type columnarregions 3 are arrayed successively between the adjacent p-type baselayers 4. A pitch P₁ of the p-type columnar regions 3 (an example of afirst pitch in the present invention) is 10 μm to 20 μm. The pitch P₁ isa single repeating unit of the p-section columnar region 3 and the n⁻base layer 2 between the adjacent p-type columnar region 3, and refersto the length in the direction along the surface of the n⁻ base layer 2of this repeating unit. In this embodiment, the p-type columnar regions3 are arranged in the middle of the respective p-type base layers 4 inthe widthwise direction, and thus, the pitch P₁ coincides with the pitchof the cells 13 (cell pitch).

The side faces of the respective p-type columnar regions 3 along thethickness direction of the n⁻ base layer 2 serve as recesses andprotrusions with periodic protrusions along this thickness direction. Itis preferable that the thickness of the n⁻ base layer 2 from the bottomof the respective p-type columnar regions 3 to the rear surface of then⁻ base layer 2 be at least 15 μm. If the thickness is at least 15 μm,then it is possible to achieve a breakdown voltage of 600V or above.

The interface of the p-type base layer 4 and p-type columnar region 3with the n− base layer 2 is the p-n junction area, and this forms aparasitic diode (body diode) 14.

An n⁺ source layer 5 is formed in the inner area of the p-type baselayer 4 of the respective cells 13 in a plan view. The n⁺ source layer 5is selectively formed on the surface of the p-type base layer 4 in thisarea. The n⁺ source layer 5 may be formed by selective ion implantationof an n-type impurity into the p-type base layer 4. An example of thisn-type impurity is as described above. The n⁺ source layer 5 is formedin the p-type base layer 4 so as to be positioned inside at a prescribeddistance from the periphery (the interface of the p-type base layer 4with the n⁻ base layer 2) of the p-type base layer 4. In this manner,the surface of the p-type base layer 4 is interposed between the n⁺source layer 5 and n⁻ base layer 2 in a surface area of thesemiconductor layer that includes the n⁻ base layer 2, p-type base layer4, and the like. This interposed surface is provided as a channel region15.

In this embodiment, as shown in FIG. 1, the n⁺ source layers 5 areformed in stripe shapes in a plan view and formed on an area outside therespective side faces of the p-type columnar regions 3. The channelregions 15 have a stripe shape in accordance with the shape of the n⁺source layers 5.

The gate insulating film 6 may be a silicon oxide film, a siliconnitride film, a silicon oxynitride film, a hafnium oxide film, analumina film, a tantalum oxide film, or the like, for example. The gateinsulating film 6 is formed so as to cover at least the surface of thep-type base layer 4 in the channel region 15. In this embodiment, thegate insulating film 6 is formed so as to cover a portion of the n⁺source layer 5, the channel region 15, and the surface of the n⁻ baselayer 2. More specifically, the gate insulating film 6 has a patternwith openings in the center areas of the p-type base layers 4 of therespective cells 13 and in the inner peripheral area of the n⁺ sourcelayer 5 continuing from this area.

The gate electrode 7 is formed so as to face the channel region 15across the gate insulating film 6. The gate electrode 7 may be made ofpolysilicon that has had impurities implanted to lower the resistancethereof, for example. In this embodiment, the gate electrode 7 hasapproximately the same pattern as the gate insulating film 6 and coversthe surface of the gate insulating film 6. In other words, the gateelectrode 7 is arranged above a portion of the n⁺ source layer 5, thechannel region 15, and the surface of the n⁻ base layer 2. Morespecifically, the gate electrode 7 has a pattern with openings in thecenter areas of the p-type base layers 4 of the respective cells 13 andin the inner peripheral area of the n⁺ source layer 5 continuing fromthis area. In other words, the gate electrodes 7 are formed so as tomutually control a plurality of the cells 13. This forms a planar gatestructure.

The interlayer insulating film 12 is made of an insulating material suchas a silicon oxide film, a silicon nitride film, or TEOS (tetraethylorthosilicate), for example. The interlayer insulating film 12 coversthe top and side faces of the gate electrode 7 and has contact holes 16in the center areas of the p-type base layers 4 of the respective cells13 and the inner periphery areas of the n⁺ source layer 5 continuingfrom this area.

The source electrode 8 is made of aluminum or another metal. The sourceelectrode 8 covers the surface of the interlayer insulating film 12 andis formed so as to fit into the contact holes 16 in the respective cells13. This causes the source electrode 8 to be in ohmic contact with then⁺ source layer 5. Accordingly, the source electrode 8 is connected tothe plurality of cells 13 in parallel, and all of the current flowing tothe plurality of the cells 13 flows through the source electrode 8. Thesource electrode 8 is also in ohmic contact with the p-type base layers4 of the respective cells 13 through the contact holes 16 and stabilizesthe potential of the p-type base layers 4.

The n⁺ contact layer 9 is formed across the entire rear surface of then⁻ base layer 2. The n⁺ contact layer 9 is formed at a depth such that agap is present between the bottom of the p-type columnar region 3 andthe n⁺ contact layer 9. The n⁻ base layer 2 is present between thep-type columnar region 3 and the n⁺ contact layer 9.

The p⁺ collector layer 10 is selectively formed on the rear surface ofthe n⁻ base layer 2, and a plurality of the p⁺ collector layers 10 arearrayed continuously along this rear surface. In this embodiment, asshown by the cross-hatching in FIG. 1, the p⁺ collector layers 10 arerespectively formed in a stripe shape that is parallel to the p-typecolumnar regions 3 in a plan view. This causes the p⁺ collector layers10 and the n⁺ contact layers 9 between the adjacent p⁺ collector layers10 to be alternately exposed in a stripe shape on the rear surface ofthe n⁻ base layer 2.

A pitch P₂ of the p⁺ collector layer 10 (an example of a second pitch ofthe present invention) is greater than the pitch P₁ of the p-typecolumnar region 3. This allows the semiconductor device 1 to selectivelyhave, in the thickness direction of the n⁻ base layer 2, p-type columnarregions 3 that face the respective p⁺ collector layers 10 and p-typecolumnar regions 3 that face the n-type portion between the adjacent p⁺collector layers 10 but not the p⁺ collector layer 10 itself.

The pitch P₂ is a single repeating unit of the p⁺ collector layer 10 andthe n⁺ contact layer 9 between the adjacent p⁺ collector layers 10, andrefers to the length in the direction along the surface of the n⁻ baselayer 2 of this repeating unit. In this repeating unit, the ratio (ofwidths) of the p⁺ collector layer 10 and the n⁺ contact layer 9 is 1:1in the present embodiment, but this can be modified as appropriate. Inthis repeating unit, the ratio (of widths) of the p⁺ collector layer 10and n⁺ contact layer 9 may be set at 50% to 80% of the occupancy of thep⁺ collector layer 10 with respect to the entire rear surface of the n⁻base layer 2.

The pitch P₂ of the p⁺ collector layer 10 has no particular limitationsas long as it is larger than the pitch P₁, but it is preferable that thepitch P₂ be 2 to 5 times that of the pitch P₁. This makes it possible toachieve a well-balanced and favorable ON-resistance for low voltageranges and for high voltage ranges of the semiconductor device 1. InFIGS. 1 and 2, the pitch P₂ is shown as two times larger than the pitchP₁ due to space constraints in the drawing, but the pitch P₂ may bethree, four, five, six times larger or more than the pitch P₁.Accordingly, in FIGS. 1 and 2, where the pitch P₂=2×pitch P₁, each ofthe p⁺ collector layers 10 faces one p-type columnar region 3 along adirection perpendicular to the p-type columnar region 3, but if thepitch P₂>2×pitch P₁, then each of the p⁺ collector layers 10 may face aplurality of the adjacent p-type columnar regions 3 so as to straddlethese. The specific size of the pitch P₂ is 5 μm to 200 μm if the pitchP₁ of the p-type columnar region 3 is 5 μm to 20 μm as described above,for example.

Furthermore, the p⁺ collector layers 10 have an impurity concentrationof 1×10¹⁷ cm⁻³ to 1×10²² cm⁻³. The p⁺ collector layer 10 is formed so asto penetrate the n⁺ contact layer 9 in the thickness direction from therear surface of the n⁻ base layer 2 and to reach the n⁻ base layer 2.The p⁺ collector layer 10 has a depth of 0.2 μm to 3 μm from the rearsurface of the n⁻ base layer 2. The width of the p⁺ collector layer 10is 5 μm to 200 μm.

The drain electrode 11 is made of aluminum or another metal. The drainelectrode 11 is formed on the rear surface of the n⁻ base layer 2 so asto contact the n⁺ contact layers 9 and the p⁺ collector layers 10. Inthis manner, the drain electrode 11 is connected to the plurality ofcells 13 in parallel, and all of the current flowing to the plurality ofthe cells 13 flows through the drain electrode 11. In this embodiment,the n⁺ contact layer 9 is formed on the rear surface of the n⁻ baselayer 2; thus, the drain electrode 11 can be in favorable ohmic contactwith the n⁻ base layer 2.

If a DC power supply is connected between the source electrode 8 and thedrain electrode 11 with the drain electrode 11 having a high potentialand the source electrode 8 having a low potential, then a reverse-biaswill be given to the parasitic diode 14. At this time, if a controlvoltage that is smaller than the prescribed threshold voltage is appliedto the gate electrode 7, then none of the current paths will be formedbetween the source/drain. In other words, the semiconductor device 1turns OFF. On the other hand, if a control voltage that is greater thanor equal to the threshold voltage is applied to the gate electrode 7,then electrons will be attracted to the surface of the channel region 15and an inversion layer (channel) will be formed. This results inconduction between the n⁺ source layer 5 and the n⁻ base layer 2. Inother words, a current path is formed from the source electrode 8 to thedrain electrode 11 through the n⁺ source layer 5, inversion layer of thechannel region 15, and the n⁻ base layer 2, in this order. In otherwords, the semiconductor device 1 turns ON.

With this configuration, a plurality of the p⁺ collector layers 10 areselectively formed on the rear surface of the n⁻ base layer 2;therefore, both the n⁻ base layer 2 and the p⁺ collector layer 10 areexposed on this rear surface. This forms the drain electrode 11 on therear surface of the n⁻ base layer 2 so as to contact both the exposed n⁻base layer 2 and the p⁺ collector layers 10, thereby making it possibleto provide the semiconductor device 1 that has MOSFET characteristicscapable of forming a set with excellent efficiency in low voltage rangesand that also has IGBT characteristics capable of generatingconductivity modulation in high voltage ranges.

Meanwhile, the respective occupancies of the n⁻ base layer 2 and the p⁺collector layers 10 with respect to the entire rear surface of the n⁻base layer 2 are smaller than regular MOSFETs and IGBTs, where theentire rear surface is occupied by only an n-type or p-type area.Therefore, if the area of the n⁻ base layer 2 or the p⁺ collector layers10 is increased, then the area of the other will become smaller. As aresult, the contact resistance of the drain electrode 11 to theserelatively small layers is increased, and the reducing effect of theon-resistance is weakened. In other words, there is a trade-off betweenthe MOSFET characteristics and the IGBT characteristics given to thesemiconductor device 1.

After earnest and diligent research, the inventors of the presentinvention were able to evenly reduce the ON-resistance in low voltageranges and high voltage ranges, not by matching the pitch P₂ of the p⁺collector layer 10 to the pitch P₁ of the p-type columnar region 3(pitch P₁=pitch P₂), but by making the pitch P₂ larger than the pitch P₁(pitch P₂>pitch P₁). As a result, this semiconductor device 1 can haveoptimal device characteristics for a variety of applications.

When the semiconductor device 1 is applied to an inverter circuit thatdrives an inductive load such as in an electric motor, sometimes thesource electrode 8 has a higher potential than the drain electrode 11,turning the parasitic diode 14 ON, and causing current to flow throughthis parasitic diode 14. Thereafter, if the source electrode 8 has alower potential than the drain electrode 11, then the parasitic diode 14becomes reverse-biased and turns OFF. When the parasitic diode 14 turnsOFF at this time, the depletion layer spreads from the p-n junctionthereof, the carriers (holes) in the p-type base layer 4 and p-typecolumnar region 3 move towards the source electrode 8 and the carriers(electrons) inside the n⁻ base layer 2 move towards the drain electrode11.

The movement of these carriers causes current to flow in the reversedirection of when the parasitic diode 14 is ON. This current is calledthe reverse recovery current. The reverse recovery current increases andthen decreases. When the forward current of the diode becomes zero, thetime it takes for the size of the reverse recovery current to decreaseto 10% of the peak value thereof is called the reverse recovery time.When the change in the reverse recovery current (di/dt) is large,sometimes oscillation (ringing) occurs until the current reaches zero.Such a reverse recovery characteristic is referred to as a hard recoveryand causes noise and malfunctioning.

The trap level area 32 contributes to shortening the reverse recoverytime. The depletion layer reducing area 30 also contributes to reducinghard recovery.

The trap level area 32 is an area formed by irradiating heavy particlesfrom the rear surface side of the n⁻ base layer 2. In the trap levelarea 32 there are a large number of recombination centers where carriersare trapped and dissipated by being recombined. This makes it possibleto quickly dissipate the carriers when the parasitic diode 14 turns OFF,and thus, the reverse recovery time and the reverse recovery current canbe reduced.

The trap level area 32 is locally formed so as to thinly spread (at athickness of approximately 1 μm to 3 μm, for example) from the rearsurface of the n⁻ base layer 2 to a prescribed depth in the n⁻ baselayer 2. The trap level area 32 may be in contact with the p-typecolumnar regions 3, or may be positioned between the bottom of thep-type columnar regions 3 and the p⁺ collector layers 10 while not incontact with the p-type columnar regions 3. The trap level area 32 beingcloser to the bottom of the p-type columnar regions 3 effectivelyshortens the reverse recovery time, while being further from the bottomof the p-type columnar regions 3 effectively reduces drain/sourceleakage current. To reduce both the reverse recovery time and thedrain/source leakage current, it is preferable that the center positionof the trap level area 32 in the thickness direction thereof be locatedin a 5 μm to 10 μm range from the bottom of the p-type columnar regions3 towards the p⁺ collector layers 10. This makes it possible to make thereverse recovery time 80 ns or less and to make the drain/source leakagecurrent several μA or less, for example. Accordingly, the parasiticdiode 14 can be used as an FRD (fast recovery diode) for thesemiconductor device 1 by operating like an IGBT in high voltage ranges.As a result, FRDs are not needed in the semiconductor device 1.

Irradiation with heavy particles such as protons, ³He⁺⁺, or ⁴He⁺⁺ can beused for formation of the trap level area 32. Among these, helium nuclei(³He⁺⁺ or ⁴He⁺⁺), which have a large mass, are preferable due to theirability to have a narrowed distribution area in the thickness directionof the recombination centers, and the recombination centers can belocally distributed within a narrow range with respect to this thicknessdirection. The depletion layer reducing area 30 is an area formed byirradiating heavy particles from the rear surface side of the n⁻ baselayer 2 and then turning these heavy particles into donors through heattreatment. The heavy particles that have become donors suppress thespread of the depletion layer, which spreads from the p-n junction ofthe parasitic diode 14 when the parasitic diode 14 is turned OFF. Thisreduces the speed at which the depletion layer spreads, and therefore,it is possible to suppress the speed of change of the reverse recoverycurrent and to reduce hard recovery.

The depletion layer reducing area 30 is formed so as to spread thickly(thicker than the trap level area 32; a thickness of approximately 5 μmto 10 μm, for example, for example) from the rear surface of the n⁻ baselayer 2 to a prescribed depth in the n⁻ base layer 2. The depletionlayer reducing area 30 may be in contact with the p-type columnarregions 3 or may not be in contact with the p-type columnar regions 3.The depletion layer reducing area 30 may have a portion that overlapswith the respective p-type columnar regions 3 or may not have a portionthat overlaps with the respective p-type columnar regions 3. Thedepletion layer reducing area 30 may be entirely positioned between thebottom of the p-type columnar regions 3 and the p⁺ collector layers 10.The depletion layer reducing area 30 includes donors; thus, it ispreferable that the areas of the depletion layer reducing area 30overlapping the respective p-type columnar regions 3 be as few aspossible, so as not to damage the functioning of the p-type columnarregions 3. It is preferable that the depletion layer reducing area 30 beclose to the p-type columnar regions 3 in order to reduce the spread ofthe depletion layer. As shown in FIG. 2, it is preferable that thearrangement of the depletion layer reducing area 30 be chosen such thatthe top edge of the depletion layer reducing area 30 approximatelycoincides with the bottom of the p-type columnar regions 3.

Irradiation with heavy particles such as protons, ³He⁺⁺, or ⁴He⁺⁺ can beused for formation of the depletion layer reducing area 30. Among these,protons, which have a small mass, can be introduced so as to be widelydistributed in the thickness direction; therefore, protons are suitablefor the formation of the thick depletion layer reducing area 30. Protonscan also be turned into donors with heat treatment performed at arelatively low temperature (350° C. to 450° C., for example). Therefore,it is possible to perform irradiation with the protons and to turn theprotons into donors (heat treatment) before and after formation of thedrain electrode 11 and the like, for example. Accordingly, using protonsincreases the degree of freedom in the relevant processes. Thearrangement of the depletion layer reducing area 30 and the trap levelarea 32 described above can be combined together as desired.

FIGS. 3A to 3J shows the sequence of a portion of the steps ofmanufacturing the semiconductor device 1. First, as shown in FIG. 3A, aninitial base layer 18 is epitaxially grown on a substrate 17 whileperforming injection of an n-type impurity. The parameters for theepitaxial growth are 5.0 Ω·cm and a thickness of 50 μm. The parametersfor the epitaxial growth are 5.0 Ω·cm and a thickness of 50 μm. Ann-type silicon substrate can be used as the substrate 17, but thissubstrate 17 will be removed in a subsequent step; thus, there is noneed for high-quality material when a cheap substrate can be used.

Next, as shown in FIG. 3B, a plurality of n-type semiconductor layers 19in which the implantation positions of the p-type impurity arevertically overlapping each other are stacked on the initial base layer18 through multi-epitaxial growth. This multi-epitaxial growth involvesrepeating a step that forms the thin n-type semiconductor layer 19 at 5Ω·cm/6 μm while selectively implanting the p-type impurity (B ions at 50keV, 5.3×10¹³ cm⁻², implantation angle of 0°) into a prescribedhorizontal position. This integrates the plurality of n-typesemiconductor layers 19 with the initial base layer 18 and forms the n⁻base layer 2.

Next, as shown in FIG. 3C, annealing (1000° C. to 1200° C.) is performedfor drive diffusion of the p-type impurity of the plurality of then-type semiconductor layers 19. This forms the p-type columnar regions3.

Next, the p-type impurity is selectively implanted (B ions at 50 keV,5.0×10¹⁵ cm⁻², implantation angle of 7°) at a relatively low energy intothe surface of the n⁻ base layer 2 to form the p-type base layers 4. Inthe p-type base layers 4 in a plan view, an n-type impurity isselectively implanted (P ions at 130 keV, 2.0×10¹⁵ cm⁻², implantationangle of 7°) into a looped area of a prescribed width that has an outeredge at a position receding a prescribed distance inwards from the outerperiphery of the p-type base layer 4. This forms the n⁺ source layer 5.

Next, the gate insulating films 6 are formed so as to respectively coverthe n⁻ base layer 2 and the surface (surface of the semiconductorcrystal) of the p-type base layers 4. These gate insulating films 6 maybe formed by thermal oxidation of the semiconductor crystal surface. Thegate electrodes 7 are formed on the respective gate insulating films 6.The gate electrodes 7 may be formed by attaching impurities and forminga low-resistance polysilicon film, and then selectively etching thispolysilicon film by photolithography, for example. The gate insulatingfilms 6 may be patterned at the same time as this etching, and the gateelectrodes 7 and the gate insulating films 6 may be formed in the samepattern. The interlayer insulating films 12 are formed (at a thicknessof 32000 Å, for example) so as to cover the respective gate electrodes7, and the contact holes 16 are formed in these interlayer insulatingfilms 12 by photolithography. Next, the source electrode 8 is formed onthe interlayer insulating films 12, and heat treatment is performed asnecessary for formation of an ohmic junction through alloying. Theformation of the source electrode 8 may be a step that includes a stepof forming a Ti/TiN barrier film (250/1300 Å, for example) and a step ofdepositing an AlCu film (4.2 μm, for example) on the barrier film.Thereafter, a surface protective film (not shown) is formed (at athickness of 16000 Å, for example), and a pad opening is formed in thissurface protective film that exposes a portion of the source electrode 8as a pad.

Next, as shown in FIG. 3D, a grinder is used to grind the substrate 17from the rear surface thereof, for example. This grinding is performedso as to completely remove the substrate 17, expose the rear surface ofthe n⁻ base layer 2, and to leave the thickness of the n⁻ base layer 2at at least 30 μm directly below the p-type columnar regions 3. Aftergrinding, the rear surface of the n⁻ base layer 2 is spin etched, whichgives the rear surface a mirror finish.

In this manner, the n⁻ base layer 2 is supported by the substrate 17through several of the manufacturing steps; thus, it is possible to makethe transport and handling of the n⁻ base layer 2 easier. It is possibleto consecutively perform the grinding of the n⁻ base layer 2 after thegrinding of the substrate 17, thus allowing the thickness of the n⁻ baselayer 2 directly under the p-type columnar regions 3 to be adjusted withease.

Thereafter, as shown in FIG. 3E, a first heavy particle irradiation isperformed from the rear surface of the n⁻ base layer 2. Material with arelatively small mass, such as protons, are used as the heavy particles(first heavy particles) for the irradiation at this time. Thereafter,low-temperature heat treatment (low-temperature annealing) is performed.This turns the heavy particles used for irradiation into donors. Whenusing protons as the heavy particles, it is possible to turn the protonsthat have been introduced into donors by a heat treatment at 350° C. to450° C. (360° C., for example) for 30 minutes to 90 minutes (60 minutes,for example).

The depletion layer reducing area 30 is formed in this manner by thefirst heavy particle irradiation and the following low-temperature heattreatment. If the energy during irradiation with the first heavyparticles is increased, then the depth of the first heavy particles willbe greater, thus forming the depletion layer reducing area 30 at alocation that is far from the rear surface of the n⁻ base layer 2. Ifthe energy is decreased, then the depth of the heavy particles will beless, thus forming the depletion layer reducing area 30 at a locationthat is close to the rear surface of the n⁻ base layer 2. Therefore, theenergy for the first heavy particle irradiation is set in accordancewith the placement of the depletion layer reducing area 30. The energyfor the first heavy particle irradiation is set such that at least aportion of the depletion layer reducing area 30 is located between thebottom of the p-type columnar regions 3 and the p⁺ collector layers 10(approximately 8 MeV, for example). The dose of the first heavyparticles (protons, for example) may be approximately 5×10¹³ ions/cm² to1×10¹⁴ ions/cm², for example.

Next, as shown in FIG. 3F, a second heavy particle irradiation isperformed from the rear surface of the n⁻ base layer 2. Materials with arelatively large mass, such as helium nuclei (³He⁺⁺ or ⁴He⁺⁺), are usedas the heavy particles (second heavy particles) for the irradiation atthis time. Thereafter, low-temperature heat treatment (low-temperatureannealing) is performed. This activates the second heavy particles usedfor irradiation. When using helium nuclei (³He⁺⁺ or ⁴He⁺⁺) as the secondheavy particles, it is possible to activate the helium nuclei that havebeen introduced by a heat treatment at 320° C. to 380° C. (350° C., forexample) for 30 minutes to 120 minutes (60 minutes, for example).

The trap level area 32 is formed in this manner. If the energy duringirradiation with the second heavy particles is made increased, then thedepth of the second heavy particles will be greater, thus forming thetrap level area 32 at a location that is far from the rear surface ofthe n⁻ base layer 2. If the energy is decreased, then the depth of thesecond heavy particles will be less, thus forming the trap level area 32at a location that is close to the rear surface of the n⁻ base layer 2.Therefore, the energy for irradiation of the second heavy particles isset in accordance with the placement of the trap level area 32. Theenergy for the second heavy particle irradiation is set such that thetrap level area 32 is located between the bottom of the p-type columnarregions 3 and the p⁺ collector layers 10 (approximately 23 MeV, forexample). The dose of the heavy particles may be approximately 5×10¹⁰ions/cm² to 5×10¹² ions/cm², for example.

Next, as shown in FIG. 3G, the n⁺ contact layer 9 is formed byimplanting an n-type impurity (As ions at 30 keV, 1.0×10¹⁵ cm⁻²,implantation at 0°) in the entire rear surface of the n⁻ base layer 2and then performing an annealing treatment.

Next, as shown in FIG. 3H, a photoresist 20 is formed by selectivelyexposing the rear surface of the n⁻ base layer 2. First, B ions areimplanted through this photoresist 20 at 100 keV, 1.0×10¹⁵ cm⁻² at a 7°tilt angle. Next, BF₂ ions are implanted at an energy that is less thanin the step of implanting the B ions, or more specifically, at 30 keV,1.0×10¹⁵ cm⁻², 7° (same tilt angle). During this time, it is possible toavoid channeling in which the ions deeply penetrate the n⁻ base layer 2by the B ions and BF₂ ions being implanted at an incline with aprescribed tilt angle, rather than implanting perpendicular to the rearsurface of the n⁻ base layer 2. Thereafter, the photoresist 20 isremoved by ashing, for example.

Next, as shown in FIG. 3I, the B ions and BF₂ ions implanted in theprevious step are activated by performing a laser annealing treatment onthe n⁻ base layer 2. This changes some of the conductivity types of then⁺ contact layer 9 from n-type to p-type and forms the p⁺ collectorlayers 10.

At this time, high-temperature (approximately 1500° C., for example)annealing is not performed, thus making it possible to prevent thesource electrode 8 from melting. In other words, metal parts such as thesource electrode 8 that melt easily in a high temperature environmentcan be made before this annealing treatment. Therefore, a large portionor all of the structure on the surface side of the n⁻ base layer 2 canbe made before the annealing treatment. As a result, the front and rearsurface of the n⁻ base layer 2 do not have to be reversed multipletimes, thereby making it possible to improve manufacturing efficiency.

Next, as shown in FIG. 3J, the drain electrode 11 is formed on the rearsurface of the n⁻ base layer 2 and a heat treatment for forming an ohmicjunction through alloying is performed as necessary. The forming of thedrain electrode 11 may be a step of sputtering Ti, Ni, Au, and Ag inthis order.

The semiconductor device 1 in FIGS. 1 and 2 can be obtained through thesteps described above.

<Modification Examples of Layout of P-type Columnar Regions 3 and p⁺Collector Layers 10>

Next, modification examples of the layout of the p-type columnar regions3 and p⁺ collector layers 10 will be described with reference to FIGS. 4to 7. First, in FIGS. 4 and 5, a modification example of the layout ofthe p⁺ collector layers 10 in relation to the striped p-type columnarregions 3 is shown.

Specifically, in FIG. 4, the p⁺ collector layers 10 are formed instripes that intersect the stripe shaped p-type columnar regions 3 in aplan view. More specifically, the p⁺ collector layers 10 are formed instripe shapes orthogonal to the p-type columnar regions 3. With thisconfiguration in FIG. 4, the respective p⁺ collector layers 10 areformed in a continuous manner across the stripe-shaped p-type columnarregions 3 and evenly face all of the p-type columnar regions 3. As aresult, it is possible to eliminate variation in area of the p⁺collector layers 10 between the cells 13; therefore, variation inon-resistance between the cells 13 can be minimized. In FIG. 4, thesep-type columnar regions 3 and p⁺ collector layers 10 are shown as beingorthogonal to each other as an example of the stripe-shaped p⁺ collectorlayers 10 intersecting the p-type columnar regions 3, but the p⁺collector layers 10 may intersect the p-type columnar regions 3 at atilted angle such as an acute angle or an obtuse angle.

In FIG. 5, the p⁺ collector layers 10 are arranged apart from each otherin a grid shape in a plan view, and the respective p⁺ collector layers10 are formed in diamond shapes that intersect (go across) the p-typecolumnar regions 3 so as to straddle a plurality of the adjacent p-typecolumnar regions 3. The shape of the respective p⁺ collector layers 10may be a diamond shape as shown in FIG. 5, or may be another polygonalor circular shape. With this configuration in FIG. 5, the p⁺ collectorlayers 10 are not formed in a continuous manner across the stripe shapedp-type columnar regions 3 as in the configuration in FIG. 4 but arearrayed in a periodic grid shape, thus making it possible to equallyface all of the p-type columnar regions 3 in a manner similar to theconfiguration in FIG. 4. As a result, it is possible to eliminatevariation in area of the p⁺ collector layers 10 between the cells 13;therefore, variation in on-resistance between the cells 13 can bereduced.

Next, in FIGS. 6 and 7, a modification example is shown of the layout ofthe p⁺ collector layers 10 in relation to diamond-shaped p-type columnarregions 3. In other words, in FIGS. 6 and 7, the p-type columnar regions3 are formed in the inner areas of the respective p-type base layers 4that are arranged apart from each other in a grid shape on the surfaceof the n⁻ base layer 2. The n⁺ source layers 5 are formed so as toencompass the respective p-type columnar regions 3. The shape of therespective p-type base layers 4 may be a diamond shape as shown in FIGS.6 and 7, or may be another polygonal or circular shape. The shape of thep-type columnar regions 3 may also be a diamond shape in accordance withthe respective p-type base layers 4, or may be another polygonal orcircular shape.

The p⁺ collector layers 10 are formed in stripe shapes parallel to eachother in FIG. 6, and in FIG. 7 are formed in diamond shapes larger thanthe p-type base layers 4. In FIG. 7, the p⁺ collector layers 10 arearranged apart from each other in a grid shape in a plan view.

The modification examples shown in FIGS. 4 to 7 are merely examples, andthe layout of the p-type columnar regions 3 and p⁺ collector layers 10can be modified as appropriate within the scope of the presentinvention.

<Modification Examples of Manufacturing Steps of P-type Columnar Regions3>

Next, modification examples of manufacturing steps of the p-typecolumnar regions 3 will be described with reference to FIGS. 8A to 8D.In the previous explanations, as shown in FIGS. 3A to 3C, the p-typecolumnar regions 3 are formed by an annealing treatment after theplurality of n-type semiconductor layers 19 has been formed bymulti-epitaxial growth while implanting a p-type impurity, which isafter the initial base layer 18 is formed. The p-type columnar regions3, however, may be formed by the steps in FIGS. 8A to 8D, for example.

Specifically, first the n⁻ base layer 2 is epitaxially grown on thesubstrate 17. Next, as shown in FIG. 8A, a hard mask 24 is formed on then⁻ base layer 2. After the hard mask 24 is patterned, the n⁻ base layer2 is dry etched through this hard mask 24. This forms trenches 25 in then⁻ base layer 2.

Next, as shown in FIG. 8B, the hard mask 24 is removed, and thereafterthe p-type semiconductor layer 26 is epitaxially grown from the insideof the trenches 25 until the surface of the n⁻ base layer 2 is covered.

Next, as shown in FIG. 8C, the p-type semiconductor layer 26 outside thetrenches 25 covering the surface of the n⁻ base layer 2 is removed byetchback, for example. This forms the p-type columnar regions 3, whichare embedded in the trenches 25.

Thereafter, as shown in FIG. 8D, steps similar to FIG. 3C and stepssimilar to FIGS. 3D to 3J may be performed.

With this method, the p-type columnar regions 3 are formed by embeddingthe p-type semiconductor layer 26 in the trenches 25, thus allowing theside faces of the respective p-type columnar regions 3 along thethickness direction of the n⁻ base layer 2 to be made flat along thesame direction.

<Embodiment 2>

FIG. 9 is a schematic cross-sectional view of a semiconductor device 31according to Embodiment 2 of the present invention. In FIG. 9, portionscorresponding to the portions in FIG. 2 are assigned the same referencecharacters and descriptions thereof will be omitted.

The semiconductor device 31 in FIG. 9 includes an n-type base layer 36instead of an n⁻ base layer 2 made of a single layer. This n-type baselayer 36 is made of a multilayer structure of n⁺ substrate 33 and an n⁻drift layer 34 formed on the n⁺ substrate 33. In the n-type base layer36, the n⁻ drift layer 34 has a relatively low impurity concentration,and the n⁺ substrate 33 has a relatively high impurity concentration. Inthis manner, the n⁺ substrate 33 both supports the n⁻ drift layer 34 andacts as the n⁺ contact layer 9 described above.

p⁺ collector layers 35 are formed so as to reach the rear surface of then⁻ drift layer 34 by penetrating the respective n⁺ substrate 33 in thethickness direction from the rear surface of the n⁺ substrate 33. Thisexposes the p⁺ collector layers 35 to the rear surface of the n⁺substrate 33. The p⁺ collector layers 35 are similar to theabove-mentioned p⁺ collector layers in terms of a pitch P₂, impurityconcentration, shape, and the like.

FIGS. 10A to 10E show the sequence of a portion of the steps ofmanufacturing the semiconductor device 31 in FIG. 9.

To manufacture this semiconductor device 31, as shown in FIG. 10A, firsta photoresist 27 selectively exposing the surface of the n⁺ substrate 33is formed on the n⁺ substrate 33 (an n⁺ silicon substrate, for example).Ion implantation of a p-type impurity is performed through thisphotoresist 27. The ion implantation may be performed according to thestep in FIG. 3H. After ion implantation, the photoresist 27 is removedby ashing, for example.

Next, as shown in FIGS. 10B and 10C, an initial base layer 18 is formedon the n⁺ substrate 33 in a manner similar to the steps in FIGS. 3A and3B, and thereafter a plurality of n-type semiconductor layers 19 arestacked to form the n⁻ drift layer 34. This forms the n-type base layer36, which is made of the n⁺ substrate 33 and the n⁻ drift layer 34.

Next, as shown in FIG. 10D, an annealing treatment (1000° C. to 1200°C.) is performed for drive diffusion of the p-type impurity in theplurality of n-type semiconductor layers 19 and the p-type impurityimplanted into the n⁺ substrate 33. This forms p-type columnar regions 3and the p⁺ collector layers 35 at the same time. Next, p-type baselayers 4, n⁺ source layers 5, gate insulating films 6, gate electrodes7, and the like are formed in a manner similar to the step in FIG. 3C.

Next, as shown in FIG. 10E, grinding is performed on the n⁺ substrate 33from the rear surface side thereof using a grinder, for example, in amanner similar to the step in FIG. 3D. This grinding is continued untilthe p⁺ collector layers 35 are exposed from the rear surface of the n⁺substrate 33. After grinding, the rear surface of the n⁺ substrate 33 isspin etched, which gives the rear surface of the n⁺ substrate 33 amirror finish.

Thereafter, the semiconductor device 31 is obtained by performing stepssimilar to those in FIGS. 3E to 3J (leaving out the steps in FIGS. 3G to3I).

With this method, the n-type base layer 36 is formed by the multilayerstructure of the n⁺ substrate 33 and the n⁻ drift layer 34. Therefore,the n⁻ drift layer 34 is supported by the n⁺ substrate 33 untilcompletion of the semiconductor device 31, thereby allowing greater easein transporting and handling of the n-type base layer 36.

Furthermore, the n⁺ substrate 33, which serves as the base layer of then-type base layer 36, can be used as the n⁺ contact layer 9 inEmbodiment 1 described above; thus, it is possible to omit the ionimplantation step as shown in FIG. 3G. This allows for the manufacturingsteps to be simplified.

<Embodiment 3>

FIG. 11 is a schematic cross-sectional view of a semiconductor device 41of Embodiment 3 of the present invention. In FIG. 11, portionscorresponding to the portions in FIG. 1 are assigned the same referencecharacters and descriptions thereof will be omitted.

Instead of an n⁻ base layer 2 made from a single layer, thesemiconductor device 41 in FIG. 11 includes an n-type base layer 44 madefrom a multilayer structure of an n⁺ substrate 42 and an n⁻ drift layer43 formed on this n⁺ substrate 42. In the n-type base layer 44, the n⁻drift layer 43 has a relatively low impurity concentration, and the n⁺substrate 42 has a relatively high impurity concentration. In thismanner, the n⁺ substrate 42 both supports the n⁻ drift layer 43 and actsas the n⁺ contact layer 9 described above.

The p⁺ collector layers 48 are formed so as to penetrate the n⁺substrate 42 in the thickness direction from the rear surface of the n⁺substrate 42 and to reach the rear surface of the n⁻ drift layer 43, ina manner similar to the p⁺ collector layers 35 in Embodiment 2 describedabove. The p⁺ collector layers 48 are exposed to the rear surface of then⁺ substrate 42, but differ from the p⁺ collector layers 35 in that thep⁺ collector layers 48 have a tapered shape where the width thereofbecomes smaller from the rear surface of the n⁻ drift layer 43 towardsthe rear surface of the n⁺ substrate 42. In other words, the width ofthe portion of the p⁺ collector layers 48 exposed to the rear surface ofthe n⁺ substrate 42 has a tapered shape that becomes less than the widthof the portion of the respective p⁺ collector layers 48 in contact withthe rear surface of the n⁻ drift layer 43.

FIGS. 12A to 12F show the sequence of a portion of the steps ofmanufacturing the semiconductor device 41 in FIG. 11.

To manufacture this semiconductor device 41, as shown in FIG. 12A, firsta photoresist 45 selectively exposing the surface of the n⁺ substrate 42is formed on the n⁺ substrate 42 (an n⁺ silicon substrate, for example).The n+ substrate 42 is dry etched through this photoresist 45. The dryetching is performed isotropically from the surface of the n⁺ substrate42 towards the rear surface. This forms trenches 46 that have a taperedshape from the opening edge towards the bottom in areas where the p⁺collector layers 48 are to be formed.

Next, as shown in FIG. 12B, a p⁺ semiconductor layer 47 is epitaxiallygrown on the n⁺ substrate 42 while implanting a p-type impurity. Thegrowth of the p⁺ semiconductor layer 47 is continued until at least thetrenches 46 are filled and the surface of the n⁺ substrate 42 is hidden.

Next, as shown in FIG. 12C, the p⁺ semiconductor layer 47 is polished byCMP. This forms the p⁺ collector layers 48, which are made from the p⁺semiconductor layer 47 left in the trenches 46.

Next, as shown in FIG. 12D, an initial base layer 18 is formed on the n⁺substrate 42 and thereafter a plurality of n-type semiconductor layers19 are stacked together in order to form an n⁻ drift layer 43, in amanner similar to the steps in FIGS. 3A and 3B. This forms the n-typebase layer 44, which is made of the n⁺ substrate 42 and the n⁻ driftlayer 43.

Next, as shown in FIG. 12E, an annealing treatment (1000° C. to 1200°C.) is performed for drive diffusion of the p-type impurity in theplurality of the n-type semiconductor layers 19. This forms p-typecolumnar regions 3. Next, p-type base layers 4, n⁺ source layers 5, gateinsulating films 6, gate electrodes 7, and the like are formed in amanner similar to the step in FIG. 3C.

Next, as shown in FIG. 12F, grinding is performed on the n⁺ substrate 42from the rear surface side thereof using a grinder, for example, in amanner similar to the step in FIG. 3D. This grinding is continued untilthe p⁺ collector layers 48 are exposed from the rear surface of the n⁺substrate 42. After grinding, the rear surface of the n⁺ substrate 42 isspin etched, which gives the rear surface of the n⁺ substrate 42 amirror finish.

Thereafter, the semiconductor device 41 is obtained by performing stepssimilar to those in FIGS. 3E to 3J (leaving out the steps in FIGS. 3G to3I).

With this method, the n-type base layer 44 is formed from a multilayerstructure of the n⁺ substrate 42 and the n⁻ drift layer 43, in a mannersimilar to Embodiment 2 described above. Therefore, the n⁻ drift layer43 is supported by the n⁺ substrate 42 until completion of thesemiconductor device 41, thereby allowing for greater ease intransporting and handling of the n-type base layer 44.

Furthermore, the n⁺ substrate 42, which serves as the base layer of then-type base layer 44, can be used as the n⁺ contact layer 9 inEmbodiment 1 described above; thus, it is possible to omit the ionimplantation step as shown in FIG. 3G. This allows for the manufacturingsteps to be simplified. Furthermore, the p⁺ collector layers 48 aregrown by epitaxial growth, thus making it possible for the impurityconcentration of the p⁺ collector layers 48 to be uniform across theentirety thereof.

The present invention can be implemented in other embodiments than thosedescribed above.

The semiconductor device may have a trench gate structure, such as asemiconductor device 51 in FIG. 13, for example. Specifically, thesemiconductor device may have a gate structure in which gate trenches 21that penetrate n⁺ source layers 5 and p-type base layers 4 from thesurface of an n⁻ base layer 2 are formed, and gate electrodes 23 arefilled in through a gate insulating film 22 into these gate trenches 21.

One or both of the above-mentioned depletion layer reducing area 30 andtrap level area 32 may be omitted.

A configuration may be used in which the conductivity type of therespective semiconductor portions of the semiconductor devices 1, 31,41, and 51 are reversed. In the semiconductor device 1, the p-type partsmay be n-type and the n-type parts may be p-type, for example. Besidesthese, various modifications in design can be made within the scope ofthe claims.

Next, descriptions are given for simulations performed to certifyseveral effects of aspects of the present invention described above.

<Simulation Example 1>

In Simulation Example 1, the manner in which the respectiveon-resistances of the low voltage ranges and high voltage ranges changein response to change of the pitch P₂ of the p⁺ collector layers 10 wasconfirmed. In Simulation Example 1, the structure of the semiconductordevice 1 in FIG. 2 is used, and the parameters of the simulation areconfigured as: occupancy of p⁺ collector layers 10=64%; and ratio ofwidth of p⁺ collector layers 10 to n⁺ contact layer 9=1:1.

The respective Id-Vd characteristics were investigated with the pitch P₂of the p⁺ collector layers 10 configured as: the same size as the pitchP₁ of the p-type columnar regions 3 (1 cell pitch); two times the pitchP₁ (2 cell pitch); four times the pitch P₁ (4 cell pitch); and eighttimes the pitch P₁ (8 cell pitch). The results are shown in FIGS. 14Aand 14B. In FIGS. 14A and 14B, the Id-Vd characteristics of an ordinaryMOSFET with no p⁺ collector layers 10 is also shown for reference.

As seen in FIG. 14A, the ON current in the high voltage ranges increasesas the pitch P₂ of the p⁺ collector layers 10 becomes larger with the 2cell pitch, 4 cell pitch, and 8 cell pitch. The amount of increasebetween the 4 cell pitch and the 8 cell pitch, however, is not as muchas the amount of increase between the 2 cell pitch and the 4 cell pitch.This means that the ON current in the high voltage ranges has aneffective increase until approximately 4 or 5 times the pitch P₁, ascompared to if the pitch P₂ of the p+ collector layers 10 were the sameas the pitch P₁ of the p-type columnar regions 3. This increase,however, reaches saturation at around 4 times the pitch P₁.

As seen in FIG. 14B, the ON current in the low voltage ranges decreasesas the pitch P₂ of the p⁺ collector layers 10 becomes larger with the 2cell pitch, 4 cell pitch, and 8 cell pitch. It is shown that thedecrease between the 4 cell pitch and the 8 cell pitch is greater thanthe decrease between the 2 cell pitch and the 4 cell pitch. Accordingly,it was found to be preferable for the pitch P₂ of the p⁺ collectorlayers 10 to be approximately 4 times or 5 times the pitch P₁ of thep-type columnar regions 3, from the viewpoint of having a relativelyhigh current in the low voltage ranges.

In summary, the results in FIGS. 14A and 14B above show that the pitchP₂ of the p⁺ collector layers 10 can be made larger than the pitch P₁ ofthe p-type columnar regions 3 (pitch P₂>pitch P₁), but in terms ofevenly reducing the on-resistance in the low voltage ranges and the highvoltage ranges, greater effects can be achieved by making the pitch P₂two times to five times larger than the pitch P₁.

<Simulation Example 2>

In Simulation Example 2, it was confirmed how the on-resistance betweenthe cells 13 change in response to changes in the layout of the p⁺collector layers 10. In Simulation Example 2, the parameters of thesimulation are configured as: occupancy of p⁺ collector layers 10 onrear surface of n⁻ base layer 2=72%; pitch P₁ of p-type columnar regions3=14.25 μm; ratio of width of p⁺ collector layers 10 to n⁺ contact layer9=1:1.

The ON-resistance (Ron) of the respective cells 13 when lA drain currentwas flowing was investigated with the pitch P₂ of the p⁺ collectorlayers 10 configured as: the same size as the pitch P₁ of the p-typecolumnar regions 3 (1 cell pitch); two times the pitch P₁ (2 cellpitch); four times the pitch P₁ (4 cell pitch); and eight times thepitch P₁ (8 cell pitch) This results are shown in FIG. 15. In FIG. 15,the simulation results of an ordinary MOSFET (0%: FET) with no p⁺collector layers 10 are also shown for reference. The solid line, dashedline, and dashed-dotted line show to what extent lateral deviations inphotolithography when forming the p⁺ collector layers 10 contributed ton⁻ sections (n⁺ contact layer 9) on the rear surface of the n⁻ baselayer 2. The dashed-dotted line PR: 0.5 μm/n-contribution (%) means thatif a 0.5 μm photolithography deviation occurs in 1 cell pitch, then theformation position of the n portion will have an approximately 50%deviation from the design position.

As understood by FIG. 15, if the p⁺ collector layers 10 have a verticallayout (the layout in FIG. 4), then there will be hardly any variationin on-resistance between the cells 13 regardless of the size of thepitch P₂ between the p⁺ collector layers 10 and the size ofphotolithography deviation.

On the other hand, if the p⁺ collector layers 10 have a parallel layout(the layout in FIG. 1) or a diamond-shaped layout (the layout in 5),then a slight variation can be seen when compared to the verticallayout. It is possible that this variation is due to the p⁺ collectorlayers 10 not equally facing all of the p-type columnar regions 3 ordeviations in photolithography. The variations in the parallel layoutand diamond-shaped layout are large when using the vertical layout as areference, and pose no issues affecting implementation.

<Embodiment 4>

FIG. 16 is a schematic plan view of a semiconductor device 101 ofEmbodiment 4 of the present invention. FIG. 17 is a cross-sectional viewalong the line II-II in FIG. 16. In FIG. 16, only the elements necessaryfor explanation are shown, and a n⁺ source layer 105, a gate electrode107, a source electrode 108, and the like, for example, are omitted.

The semiconductor device 101 is a superjunction n-channel MOSFET (metaloxide semiconductor field effect transistor).

The semiconductor device 101 includes an n⁺ drain layer 117, an n⁻ baselayer 102, p-type columnar regions 103, p-type base layers 104, p-typeassist regions 130, n⁺ source layers 105, gate insulating films 106,gate electrodes 107, a source electrode 108, and a drain electrode 111.Interlayer insulating films 112 are arranged on the respective gateelectrodes 107.

The n⁺ drain layer 117 may be made of an n⁺ semiconductor substrate (asilicon substrate, for example). The n⁺ semiconductor substrate may be asemiconductor substrate that has undergone crystal growth while beingdoped with an n-type impurity. P (phosphorous), As (arsenic), SB(antimony) or the like can be used as the n-type impurity.

The n⁺ base layer 102 is a semiconductor layer in which an n-typeimpurity has been implanted. More specifically, the n-base layer 102 maybe an n-type epitaxial layer that is epitaxially grown while implantingthe n-type impurity. The previously described material can be used asthe n-type impurity.

The p-type columnar regions 103 and p-type base layers 104 aresemiconductor layers in which a p-type impurity has been implanted. Morespecifically, the p-type columnar regions 103 and p-type base layers 104may be semiconductor layers that are respectively formed by the ionimplantation of a p-type impurity in the n− base layer 102. B (boron),Al (aluminum), Ga (gallium), or the like can be used as the p-typeimpurity.

As shown in FIG. 16, the p-type base layers 104 are selectively formedon the surface of the n⁻ base layer 102 in a plurality of areas that arearranged periodically and apart from each other in a plan view seen froma direction normal to the surface of the n⁻ base layer 102 (hereinafter,referred to as just “a plan view”). In this embodiment, this pluralityof p-type base layers 104 are formed in mutually parallel stripe shapes.The width of the respective p-type base layers 104 is 3 μm to 10 μm, forexample. The individual p-type base layers 104 and the area includingthe n⁻ base layer 102 surrounding these form cells 113. In other words,in the layout in FIG. 16, this semiconductor device 101 has a largenumber of cells 113 arrayed in stripe shapes in a plan view.

The p-type columnar regions 103 are formed in the inner area of thep-type base layer 104 of each of the cells 113 in a plan view. Morespecifically, in the present embodiment, the p-type columnar regions 103are respectively formed in stripe shapes in the center area in thewidthwise direction of the p-type base layers 104. The p-type columnarregions 103 are formed so as to continue from the respective p-type baselayers 104 and extend towards the n⁺ drain layer 117 in the n⁻ baselayer 102 to a position that is deeper than the p-type base layers 104.Accordingly, the p-type columnar regions 103 are arrayed continuouslybetween the adjacent p-type base layers 104. A pitch P₁ (an example of afirst pitch in the present invention) of the p-type columnar regions 103is 5 μm to 20 μm. The pitch P₁ includes the p-section columnar region103 and the n⁻ base layer 102 between the adjacent p-type columnarregions 103 serving as a single repeating unit, and refers to the lengthin the direction along the surface of the n⁻ base layer 102 of thisrepeating unit. In this embodiment, the p-type columnar regions 103 arearranged in the middle of the respective p-type base layers 104 in thewidthwise direction, and thus, the pitch P₁ coincides with the pitch ofthe cells (cell pitch) 113.

The p-type columnar regions 103 are each separated into top and bottomby an area 134 that is a part of the n⁻ base layer 102 interposed in themiddle of the thickness direction of the p-type columnar region 103. Thep-type columnar regions 103 each have a column 133 that includes a topcolumnar region 131 and a bottom columnar region 132 that is formedlengthwise in the depth direction of the n⁻ base layer 102 further thanthe top columnar region 131. In other words, the separated columns 133each have a shape that appears as though the respective p-type columnarregions 103 have been separated at the area 134 above the center of thedepth direction of the p-type columnar region 103. The side faces of therespective columnar regions 131 and 132 along the depth direction of then⁻ base layer 102 serve as recesses and protrusions with periodicprotrusions along the depth direction. The number of these recesses andprotrusions normally match the number of n-type semiconductor layers 119(FIG. 18A) described later, but for sake of clarity the number ofrecesses and protrusions is less than the number of layers in FIG. 17.

The top columnar region 131 is formed integrally with the p-type baselayer 104, and a parasitic diode (body diode) 114 is formed at eachinterface (p-n junction) of the respective p-type base layers 104 andthe n⁻ base layer 102. The bottom columnar region 132 is separated fromthe p-type base layer 104 by the area 134 and is electrically floating.

It is preferable that the length of the bottom columnar region 132 betwo times to ten times that of the top columnar region 131, for example.Specifically, it is preferable that the length of the top columnarregion 131 be 1 μm to 5 μm and that the length of the bottom columnarregion 132 be 2 μm to 20 μm. The length of the bottom columnar region132 may be configured such that the thickness of the n⁻ base layer 102from the bottom of the bottom columnar region 132 to the rear of the n⁻base layer 102 is at least 5 μm. If the thickness is at least 5 μm, thenit is possible to achieve a breakdown voltage of 600V or above.

If the p-type assist regions 130 are provided as in the presentembodiment, then the gap of the respective areas 134 (the distance fromthe bottom edge of the top columnar region 131 to the top edge of thebottom columnar region 132) may be 0.5 μm to 10 μm.

In the present embodiment, all of the p-type columnar regions 103 areseparated columns 133.

The respective p-type assist regions 130 are formed with a gap from thetop columnar region 131 and the bottom columnar region 132 in a positionthat is separated from the respective areas 134 in the horizontaldirection along the surface of the n⁻ base layer 102. In the presentembodiment, the p-type assist regions 130 are respectively formeddirectly below the area between the adjacent p-type base layers 104 (inother words, the boundary regions between the cells 113). A plurality ofthese p-type assist regions 130 are formed with gaps therebetween alongthe stripe direction of the respective p-type base layers 104 in theabove-mentioned areas.

The planar shape of the p-type assist regions 130 may be the dot shapeshown in FIG. 16, a rectangular shape, or the like. By scattering thesep-type assist regions 130 around in a plan view, the areas between theadjacent p-type assist regions 130 (the shaded portions in FIG. 16) canbe efficiently used as MOSFET current paths. The p-type assist regions130 may be formed in a stripe shape in these areas. In this case,current that is flowing from the drain electrode 111 to the sourceelectrode 108 will be able to avoid the p-type assist regions 130, asshown by a current path 135 in FIG. 17. The p-type assist regions 130may be semiconductor layers that are respectively formed by the ionimplantation of a p-type impurity in the n⁻ base layer 102. An exampleof this p-type impurity is as given above.

The n⁺ source layer 105 is formed in the inner area of the p-type baselayer 104 of the respective cells 113 in a plan view. The n⁺ sourcelayer 105 is selectively formed on the surface of the p-type base layer104 in this area. The n⁺ source layers 105 may be formed by selectiveion implantation of an n-type impurity into the p-type base layer 104.An example of this n-type impurity is as described above. The n⁺ sourcelayers 105 are formed in the respective p-type base layer 104 so as tobe positioned inside at a prescribed distance from the periphery (theinterface of the p-type base layer 104 with the n⁻ base layer 102) ofthe p-type base layers 104. This causes the surface of the p-type baselayer 104 to be interposed between the n⁺ source layer 105 and the n⁻base layer 102 in the surface area of the semiconductor layer includingthe n⁻ base layer 102, p-type base layer 104, and the like. Thisinterposed surface provides a channel region 115.

In this embodiment, the n⁺ source layers 105 are formed in stripe shapesin a plan view and formed on an area outside the respective side facesof the p-type columnar regions 103. The channel regions 115 have astripe shape in accordance with the shape of the n⁺ source layers 105.

The gate insulating film 106 may be a silicon oxide film, a siliconnitride film, a silicon oxynitride film, a hafnium oxide film, analumina film, a tantalum oxide film, or the like, for example. The gateinsulating film 106 is formed so as to cover at least the surface of therespective p-type base layers 104 in the channel region 115. In thisembodiment, the gate insulating films 106 are formed so as to each covera portion of the n⁺ source layer 105, the channel region 115, and thesurface of the n⁻ base layer 102. More specifically, the gate insulatingfilm 106 has a pattern with an opening in the center area of the p-typebase layers 104 of the respective cells 113 and in the inner peripheralarea of the n⁺ source layer 105 continuing from this area.

The gate electrode 107 is formed so as to face the channel region 115across the gate insulating film 106. The gate electrode 107 may be madeof polysilicon that has had impurities implanted to lower the resistancethereof, for example. In this embodiment, the gate electrode 107 hasapproximately the same pattern as the gate insulating film 106 andcovers the surface of the gate insulating film 106. In other words, thegate electrode 107 is arranged above a portion of the n⁺ source layer105, the channel region 115, and the surface of the n⁻ base layer 102.More specifically, the gate electrode 107 has a pattern with an openingin the center area of the p-type base layers 104 of the respective cells113 and in the inner peripheral area of the n⁺ source layer 105continuing from this area. In other words, the gate electrodes 107 areformed so as to mutually control a plurality of the cells 113. Thisforms a planar gate structure.

The interlayer insulating film 112 is made of an insulating materialsuch as a silicon oxide film, a silicon nitride film, or TEOS(tetraethyl orthosilicate), for example. The interlayer insulating film112 covers the top and side faces of the gate electrode 107 and hascontact holes 116 in the center area of the p-type base layers 104 ofthe respective cells 113 and the inner periphery areas of the n⁺ sourcelayer 105 continuing from this area.

The source electrode 108 is made of aluminum or another metal. Thesource electrode 108 covers the surface of the interlayer insulatingfilm 112 and is formed so as to fit into the contact holes 116 in therespective cells 113. This causes the source electrode 108 to be inohmic contact with the n⁺ source layer 105. Accordingly, the sourceelectrode 108 is connected to the plurality of cells 113 in parallel,and all of the current flowing to the plurality of the cells 113 flowsthrough the source electrode 108. The source electrode 108 is also inohmic contact with the p-type base layers 104 of the respective cells113 through the contact holes 116 and stabilizes the potential of thep-type base layers 104.

The drain electrode 111 is made of aluminum or another metal. The drainelectrode 111 is formed so as to contact the rear surface of the n⁺drain layer 117. In this manner, the drain electrode 111 is connected tothe plurality of cells 113 in parallel, and all of the current flowingto the plurality of the cells 113 flows through the drain electrode 111.

If a DC power supply is connected between the source electrode 108 andthe drain electrode 111 with the drain electrode 111 having a highpotential and the source electrode 108 having a low potential, then areverse-bias will be given to the parasitic diodes 114. At this time, ifa control voltage that is smaller than the prescribed threshold voltageis applied to the gate electrode 107, then none of the current pathswill be formed between the source/drain. In other words, thesemiconductor device 101 turns OFF. On the other hand, if a controlvoltage that is greater than or equal to the threshold voltage isapplied to the gate electrode 107, then electrons will be attracted tothe surface of the channel region 115 and an inversion layer (channel)will be formed. This connects the n⁺ source layer 105 and the n⁻ baselayer 102. In other words, the current path 135 is formed from thesource electrode 108 to the drain electrode 111 through the n⁺ sourcelayer 105, the inversion layer of the channel region 115, and the n⁻base layer 102, in this order. In other words, the semiconductor device101 turns ON.

When the semiconductor device 101 is applied to an inverter circuit thatdrives an inductive load such as in an electric motor, sometimes thesource electrode 108 has a higher potential than the drain electrode111, turning the parasitic diodes 114 ON, and causing current to flowthrough these parasitic diodes 114. If the source electrode 108 has alower potential than the drain electrode 111 thereafter, then theparasitic diodes 114 become reversed-biased and turn OFF. When theparasitic diodes 114 turn OFF at this time, the depletion layer spreadsfrom the p-n junction thereof, the carriers (holes) in the p-type baselayers 104 and p-type columnar regions 103 move towards the sourceelectrode 108 and the carriers (electrons) inside the n− base layer 102move towards the drain electrode 111.

The movement of these carriers causes current to flow in the reversedirection of when the parasitic diodes 114 are ON. This current iscalled the reverse recovery current. The reverse recovery currentincreases and then decreases. When the forward current of the diodebecomes zero, the time it takes for the size of the reverse recoverycurrent to decrease to 10% of the peak value thereof is called thereverse recovery time. When the change in the reverse recovery current(dir/dt) is large, sometimes oscillation (ringing) occurs until thecurrent reaches zero. Such a reverse recovery characteristic is referredto as a hard recovery and causes noise and malfunctioning.

In this semiconductor device 101, there are the columns 133 where therespective p-type columnar regions 103 have been separated into top andbottom, and the relatively long bottom columns 132 of the separatedcolumns 133 are electrically floating with respect to the p-type baselayers 104. Accordingly, the bottom columnar region 132 does notcontribute to the operation of the parasitic diode 114, and therefore,rapid spreading of the depletion layer during reverse-bias issuppressed. This suppresses the spread of the depletion layer towardsthe drain electrode 111, thereby suppressing the speed at which thedepletion layer spreads when the parasitic diode 114 is turned OFF. Thisreduces the speed of change of the reverse recovery current (dir/dt),and thus improves the recovery characteristics. Since the configurationis simply the column 133 in which the p-type columnar regions 103 havebeen separated, the structure is also simple.

Furthermore, although the p-type columnar regions 103 are separated, theconfiguration has a superjunction structure in which the p-type columnarregions 103 extend from the p-type base layer 104 towards the n⁺ drainlayer 117 and the p-type assist regions 130 are provided on therespective sides of the areas 134. Accordingly, depletion layersspreading in the horizontal direction from the respective top columnarregions 131 and bottom columnar regions 132 can be relayed andintegrated by the p-type assist regions 130. This also makes it possibleto achieve the inherent superjunction characteristics of favorableON-resistance and switching speed.

FIGS. 18A to 18C show the sequence of a portion of the steps ofmanufacturing the semiconductor device 101.

First, as shown in FIG. 18A, an initial base layer 118, which is oneexample of a main layer of the present invention, is formed on the n⁺drain layer 117. The parameters for epitaxial growth are 1 Ω·cm to 10Ω·cm and a thickness of 5 μm to 20 μm, for example.

Next, as shown in FIG. 18B, a plurality of the n-type semiconductorlayers 119 are stacked on the initial base layer 118 throughmulti-epitaxial growth. This multi-epitaxial growth involves repeating astep that forms the thin n-type semiconductor layer 119 (bottom mainlayer) at 1 Ω·cm to 10 Ω·cm/2 μm to 10 μm while selectively implanting(B ions at 50 keV, 5.3×10¹³ cm⁻², implantation angle of 0°) the p-typeimpurity into a first position 136 where the p-type columnar region 103will be formed. In the present embodiment, the initial base layer 118and n-type semiconductor layers 119 are combined to grow five n-typesemiconductor layers. Thereafter, an n-type semiconductor layer 138(buffer layer) with the same resistance and thickness as the n-typesemiconductor layers 119 (1 Ω·cm to 10 Ω·cm/2 μm to 10 μm) is grown as asixth epitaxial layer while implanting a p-type impurity into a secondposition 137 where the p-type assist region 130 will be formed. Thissecond position 137 is separated from the first position 136 in thehorizontal direction. Next, the n-type semiconductor layers 119 aregrown again through multi-epitaxial growth in a smaller number of stepsthan before the forming of the n-type semiconductor layer 138 (two inthis embodiment), or in other words, at a lesser thickness. Thisintegrates the plurality of n-type semiconductor layers 119 and 138 withthe initial base layer 118 and forms the n⁻ base layer 102.

Next, as shown in FIG. 18C, an annealing treatment (1000° C. to 1200°C.) is performed for drive diffusion of the p-type impurity in theplurality of the n-type semiconductor layers 119 and 138. This forms thep-type columnar regions 103 having the separated columns 133 and thep-type assist regions 130 at the same time. In other words, the p-typeimpurity diffusion in the n-type semiconductor layers 119 that are thebottom main layers provides the bottom columnar regions 132, the p-typeimpurity diffusion in the n-type semiconductor layers 119 that are thetop main lowers provides the top columnar regions 131, and the p-typeimpurity diffusion in the n-type impurity layer 138 between theseprovides the p-type assist regions 130. Accordingly, the first position136 and the second position 137 where the p-type impurities areimplanted are respectively configured in accordance with the formationlocation of the p-type columnar regions 103 and the p-type assistregions 130.

Next, the p-type impurity is selectively implanted (B ions at 50 keV,5.0×10¹⁵ cm⁻², implantation angle of 7°) at a relatively low energy intothe surface of the n⁻ base layer 102 to form the p-type base layer 104.In the p-type base layer 104 in a plan view, an n-type impurity isselectively implanted (P ions at 130 keV, 2.0×10¹⁵ cm⁻², implantationangle of 7°) into a looped area of a prescribed width that has an outeredge at a position receding a prescribed distance inwards from the outerperiphery of the p-type base layer 104. This forms the n⁺ source layer105.

Next, the gate insulating film 106 is formed so as to cover the n⁻ baselayer 102 and the surface (surface of the semiconductor crystal) of thep-type base layer 104. This gate insulating film 106 may be formed bythermal oxidation of the semiconductor crystal surface. The gateelectrode 107 is formed on the gate insulating film 106. The gateelectrode 107 may be formed by attaching impurities and forming alow-resistance polysilicon film, and then selectively etching thispolysilicon film through photolithography, for example. The gateinsulating film 106 may be patterned at the same time as this etching,and the gate electrode 107 and the gate insulating film 106 may beformed in the same pattern. The interlayer insulating film 112 is formed(at a thickness of 10000 Å, for example) so as to cover the gateelectrode 107, and the contact holes 116 are formed in this interlayerinsulating film 112 by photolithography. Next, the source electrode 108is formed on the interlayer insulating film 112, and heat treatment isperformed as necessary for formation of an ohmic junction throughalloying. The formation of the source electrode 108 may be a step thatincludes a step of forming a Ti/TiN barrier film (250/1300 Å, forexample) and a step of depositing an AlCu film (4.2 μm, for example) onthe barrier film. Thereafter, a surface protective film (not shown) isformed (at a thickness of 16000 Å, for example), and a pad opening isformed in this surface protective film that exposes a portion of thesource electrode 108 as a pad.

Thereafter, the drain electrode 111 is formed on the rear surface of then⁺ drain layer 117, and heat treatment is performed as necessary forformation of an ohmic junction through alloying. The forming of thedrain electrode 111 may be a step of sputtering Ti, Ni, Au, and Ag inthis order.

The semiconductor device 101 in FIGS. 16 and 17 can be obtained throughthe steps described above.

<Embodiment 5>

FIG. 19 is a schematic plan view of a semiconductor device 141 ofEmbodiment 5 of the present invention. FIG. 20 is a cross-sectional viewalong the line V-V in FIG. 19. In FIGS. 19 and 20, portionscorresponding to the portions in FIGS. 16 and 17 are assigned the samereference characters and descriptions thereof will be omitted.

The semiconductor device 141 differs from the above-mentionedsemiconductor device 101 in that the n⁺ drain layer 117 and the p-typeassist regions 130 have been omitted.

More specifically, the semiconductor device 141 has an n⁺ contact layer109 instead of an n⁺ drain layer 117 as a layer for making contact witha drain electrode 111.

The n⁺ contact layer 109 is formed across the entire rear surface of ann⁻ base layer 102. The n⁺ contact layer 109 is formed at a depth suchthat a gap is present between the bottom of a p-type columnar region 103and the n⁺ contact layer 109. This causes the n⁻ base layer 102 to bepresent between the p-type columnar regions 103 and the n⁺ contactlayers 109.

The semiconductor device 141 also differs from the above-mentionedsemiconductor device 101 in that p⁺ collector layers 110 are selectivelyformed on the rear surface of the n⁺ contact layers 109.

The p⁺ collector layer 110 is selectively formed on the rear surface ofthe n⁻ base layer 102, and a plurality of the p⁺ collector layers 110are arrayed continuously along this rear surface. In this embodiment, asshown by the cross-hatching in FIG. 19, the p⁺ collector layers 110 arerespectively formed in a stripe shape that is parallel to the p-typecolumnar regions 103 in a plan view. This causes the p⁺ collector layers110 and the n⁺ contact layers 109 between the adjacent p⁺ collectorlayers 110 to be alternately exposed in a stripe shape on the rearsurface of the n⁻ base layer 102.

A pitch P₂ of the p⁺ collector layer 110 (an example of a second pitchof the present invention) is greater than a pitch P₁ of the p-typecolumnar region 103. This allows the semiconductor device 141 toselectively have, in the thickness direction of the n⁻ base layer 102,p-type columnar regions 103 that face the respective p⁺ collector layers110 and p-type columnar regions 103 that face the n-type portion betweenthe adjacent p⁺ collector layers 110 but not the p⁺ collector layer 110itself.

The pitch P₂ is the p⁺ collector layer 110 and the n⁺ contact layer 109between the adjacent p⁺ collector layers 110 serving as a singlerepeating unit, and refers to the length in the direction along thesurface of the n⁻ base layer 102 of this repeating unit. In thisrepeating unit, the ratio (of widths) of the p⁺ collector layer 110 andthe n⁺ contact layer 109 is 1:1 in the present embodiment, but this canbe modified as appropriate. In this repeating unit, the ratio (ofwidths) of the p⁺ collector layer 110 and n⁺ contact layer 109 may beset at 50% to 80% of the occupancy of the p⁺ collector layer 110 withrespect to the entire rear surface of the n⁻ base layer 102.

The pitch P₂ of the p⁺ collector layer 110 has no particular limitationsas long as it is larger than the pitch P₁, but it is preferable that thepitch P₂ be 2 to 5 times that of the pitch P₁. This makes it possible toachieve a well-balanced and favorable on-resistance for low voltageranges and for high voltage ranges of the semiconductor device 141. InFIGS. 19 and 20, the pitch P₂ is shown as two times larger than thepitch P₁ due to space constraints in the drawing, but the pitch P₂ maybe three, four, five, six times larger or more than the pitch P₁.Accordingly, in FIGS. 19 and 20, where the pitch P₂=2×the pitch P₁, eachof the p⁺ collector layers 110 faces one p-type columnar region 103along a direction perpendicular to the p-type columnar region 103, butif the pitch P₂>2×the pitch P₁, then each of the p⁺ collector layers 110may face a plurality of the adjacent p-type columnar regions 103 so asto straddle these. The specific size of the pitch P₂ is 5 μm to 200 μmif the pitch P₁ of the p-type columnar region 103 is 5 μm to 20 μm asdescribed above, for example.

Furthermore, the p⁺ collector layer 110 has an impurity concentration of1×10¹⁷ cm⁻³ to 1×10²² cm⁻³. The p⁺ collector layer 110 is formed so asto penetrate the n⁺ contact layer 109 in the thickness direction fromthe rear surface of the n⁻ base layer 102 and to reach the n⁻ base layer102. The p⁺ collector layer 110 has a depth of 0.2 μm to 3 μm from therear surface of the n⁻ base layer 102. The width of the p⁺ collectorlayer 110 is 5 μm to 200 μm.

In the semiconductor device 141, the gap (between the bottom edge of atop columnar region 131 and the top edge of a bottom columnar region132) of an area 134 is narrower than in Embodiment 4 described above dueto the omission of the p-type assist regions 130. Specifically, the gapmay be 1 μm to 5 μm. This makes it possible for the top columnar region131 and the bottom columnar region 132 to be close to each other;therefore, the depletion layer spreading horizontally from the topcolumnar region 131 and the bottom columnar region 132 can be favorablyintegrated even without the p-type assist regions 130.

According to this semiconductor device 141, a plurality of the p⁺collector layers 110 are selectively formed on the rear surface of then⁻ base layer 102, thereby exposing both the n-base layer 102 and the p⁺collector layers 110 on this rear surface. This forms the drainelectrode 111 on the rear surface of the n⁻ base layer 102 so as tocontact both the exposed n⁻ base layer 102 and the p⁺ collector layer110, thereby making it possible to provide the semiconductor device 141that has MOSFET characteristics capable of forming a set with excellentefficiency in low voltage ranges and that also has IGBT characteristicscapable of generating conductivity modulation in high voltage ranges.Furthermore, the semiconductor device 141 has the columns 133 with theseparated p-type columnar regions 103, thus making it possible tofavorably reduce ON-resistance in high voltage ranges as compared to ifp⁺ collector layers 110 were provided in a semiconductor device in whichall of the p-type columnar regions 103 are continuous columnar regions139 (described later).

Meanwhile, the respective occupancies of the n⁻ base layer 102 and thep⁺ collector layer 110 with respect to the entire rear surface of the n⁻base layer 102 are smaller than regular MOSFETs and IGBTs, where theentire rear surface is occupied by only an n-type or p-type area.Therefore, if the area of the n⁻ base layer 102 or the p⁺ collectorlayer 110 is increased, then the area of the other will become smaller.As a result, the contact resistance of the drain electrode 111 to therelatively small layer is increased, and the reducing effect of theon-resistance is weakened. In other words, there is a trade-off betweenthe MOSFET characteristics and the IGBT characteristics given to thesemiconductor device 141.

After earnest and diligent research, the inventors of the presentinvention were able to evenly reduce the on-resistance in low voltageranges and high voltage ranges, not by matching the pitch P₂ of the p⁺collector layer 110 to the pitch P₁ of the p-type columnar region 103(pitch P₁=pitch P₂), but by making the pitch P₂ larger than the pitch P₁(pitch P₂>pitch P₁). As a result, this semiconductor device 101 can haveoptimal device characteristics for a variety of applications. Needlessto say, effects similar to those of the semiconductor device 101described above can also be achieved.

FIGS. 21A to 21G show the sequence of a portion of the steps ofmanufacturing the semiconductor device 141. In FIGS. 21A to 21G,portions corresponding to the portions in FIGS. 18A to 18C are assignedthe same reference characters and descriptions thereof will be omitted.

First, as shown in FIG. 21A, an initial base layer 118 is epitaxiallygrown on a substrate 142 while performing injection of an n-typeimpurity. An n-type silicon substrate can be used as the substrate 142,but this substrate 142 will be removed in a subsequent step; thus, thereis no need for high-quality material when a cheap substrate can be used.

Next, as shown in FIG. 21B, a plurality of the n-type semiconductorlayers 119, a single n-type semiconductor layer 138, and a plurality ofthe n-type semiconductor layers 119 are epitaxially grown in this orderon the initial base layer 118. During this time, the n-typesemiconductor layer 138 is formed so as to be thinner (1 μm to 5 μm, forexample) than the n-type semiconductor layers 119, and the p-typeimpurity is not implanted into the entire area of the n-typesemiconductor layer 138. In other words, the gap between the areas 134formed later is adjusted by adjusting the thickness of the n-typesemiconductor layer 138.

Next, as shown in FIG. 21C, an annealing treatment (1000° C. to 1200°C.) is performed for drive diffusion of the p-type impurity in theplurality of the n-type semiconductor layers 119 and 138. This forms thep-type columnar regions 103 having the separated columns 133. Next, thep-type base layer 104, n⁺ source layer 105, gate insulating film 106,gate electrode 107, interlayer insulating film 112, and the sourceelectrode 108 are formed using similar methods to those described above.

Next, as shown in FIG. 21D, a grinder is used to grind the substrate 142from the rear surface thereof, for example. This grinding is performedso as to completely remove the substrate 142, expose the rear surface ofthe n⁻ base layer 102, and to leave the thickness of the n⁻ base layer102 at at least 30 μm directly below the p-type columnar regions 103.After grinding, the rear surface of the n⁻ base layer 102 is spinetched, which gives the rear surface a mirror finish.

In this manner, the n⁻ base layer 102 is supported by the substrate 142through several of the manufacturing steps; thus, it is possible to makethe transport and handling of the n⁻ base layer 102 easier. It ispossible to consecutively perform the grinding of the n⁻ base layer 102after the grinding of the substrate 142, thus allowing the thickness ofthe n⁻ base layer 102 directly under the p-type columnar regions 103 tobe adjusted with ease.

Next, as shown in FIG. 21E, the n⁺ contact layer 109 is formed byimplanting an n-type impurity (As ions at 30 keV, 1.0×10¹⁵ cm⁻²,implantation at 0°) in the entire rear surface of the n⁻ base layer 102and then performing an annealing treatment.

Next, as shown in FIG. 21F, a photoresist 120 is formed by selectivelyexposing the rear surface of the n⁻ base layer 102. First, B ions areimplanted through this photoresist 120 at 100 keV, 1.0×10¹⁵ cm⁻² at a 7°implantation tilt angle. Next, BF₂ ions are implanted at an energy thatis less than in the step of implanting the B ions, or more specifically,at 30 keV, 1.0×10¹⁵ cm⁻², implantation angle of 7° (the same tiltangle). During this time, it is possible to avoid channeling in whichthe ions deeply penetrate the n⁻ base layer 102 by the B ions and BF₂ions being implanted at an incline with a prescribed tilt angle, ratherthan implanting perpendicular to the rear surface of the n⁻ base layer102. Thereafter, the photoresist 120 is removed by ashing, for example.

Next, as shown in FIG. 21G, the B ions and BF₂ ions implanted in theprevious step are activated by performing a laser annealing treatment onthe n⁻ base layer 102. This changes some of the conductivity types ofthe n⁺ contact layer 109 from n-type to p-type and forms the p⁺collector layers 110.

At this time, high-temperature (approximately 1500° C., for example)annealing is not performed, thus making it possible to prevent thesource electrode 108 from melting. In other words, metal parts such asthe source electrode 108 that melt easily in a high temperatureenvironment can be made before this annealing treatment. Therefore, alarge portion or all of the structure on the surface side of the n⁻ baselayer 102 can be made before the annealing treatment. As a result, thefront and rear surface of the n⁻ base layer 102 do not have to bereversed multiple times, thereby making it possible to improvemanufacturing efficiency.

Thereafter, the drain electrode 111 is formed on the rear surface of then⁻ base layer 102, and heat treatment is performed as necessary forformation of an ohmic junction through alloying. The forming of thedrain electrode 111 may be a step of sputtering Ti, Ni, Au, and Ag inthis order.

The semiconductor device 141 in FIGS. 19 and 20 can be obtained throughthe steps described above

<Modification Examples of Layout of P-type Columnar Regions 103 and p⁺Collector Layers 110>

Next, modification examples of the layout of the p-type columnar regions103 and p⁺ collector layers 110 will be described with reference toFIGS. 22 to 25.

First, in FIGS. 22 and 23, a modification example of the layout of thep⁺ collector layers 110 in relation to the striped p-type columnarregions 103 is shown.

Specifically, in FIG. 22, the p⁺ collector layers 110 are formed instripes that intersect the stripe-shaped p-type columnar regions 103 ina plan view. More specifically, the p⁺ collector layers 110 are formedin stripe shapes orthogonal to the p-type columnar regions 103. Withthis configuration in FIG. 22, the respective p⁺ collector layers 110are formed in a continuous manner across the stripe-shaped p-typecolumnar regions 103 and evenly face all of the p-type columnar regions103. As a result, it is possible to eliminate variation in area of thep⁺ collector layers 110 between the cells 113; therefore, variation inON-resistance between the cells 113 can be minimized. In FIG. 22, thesep-type columnar regions 103 and p⁺ collector layers 110 are shown asbeing orthogonal to each other as an example of the stripe-shaped p⁺collector layers 110 intersecting the p-type columnar regions 103, butthe p⁺ collector layers 110 may intersect the p-type columnar regions103 at a tilted angle such as an acute angle or an obtuse angle.

In FIG. 23, the p⁺ collector layers 110 are arranged apart from eachother in a grid shape in a plan view, and the respective p⁺ collectorlayers 110 are formed in diamond shapes that intersect (go across) thep-type columnar regions 103 so as to straddle a plurality of theadjacent p-type columnar regions 103. The shape of the respective p⁺collector layers 110 may be a diamond shape as shown in FIG. 23, or maybe another polygonal or circular shape. With this configuration in FIG.23, the p⁺ collector layers 110 are not formed in a continuous manneracross the stripe-shaped p-type columnar regions 103 as in theconfiguration in FIG. 22 but are arrayed in a periodic grid shape, thusmaking it possible to equally face all of the p-type columnar regions103 in a manner similar to the configuration in FIG. 22. As a result, itis possible to eliminate variation in area of the p⁺ collector layers110 between the cells 113; therefore, variation in ON-resistance betweenthe cells 113 can be minimized.

Next, in FIGS. 24 and 25, a modification example is shown of the layoutof the p⁺ collector layers 110 in relation to the diamond-shaped p-typecolumnar regions 103. In other words, in FIGS. 24 and 25, the p-typecolumnar regions 103 are formed in the inner areas of the respectivep-type base layers 104 arranged apart from each other in a grid shape onthe surface of the n⁻ base layer 102. The n⁺ source layers 105 areformed so as to encompass the respective p-type columnar regions 103.The shape of the respective p-type base layers 104 may be a diamondshape as shown in FIGS. 24 and 25, or may be another polygonal orcircular shape. The shape of the p-type columnar regions 103 may also bea diamond shape in accordance with the respective p-type base layers104, or may be another polygonal or circular shape.

The p⁺ collector layers 110 are formed in stripe shapes parallel to eachother in FIG. 24, and in FIG. 25 are formed in diamond shapes largerthan the p-type base layers 104. In FIG. 25, the p⁺ collector layers 110are arranged apart from each other in a grid shape in a plan view.

The modification examples shown in FIGS. 22 to 25 are merely examples,and the layout of the p-type columnar regions 103 and p⁺ collectorlayers 110 can be modified as appropriate within the scope of thepresent invention.

Embodiments of the present invention were described above, but thepresent invention can also be implemented in other embodiments.

As with a semiconductor device 151 shown in FIG. 26, the p-type columnarregions 103 may selectively include continuous columnar regions 139 thatcontinue from the p-type base layer 104 to the bottom edge of the bottomcolumnar region 132 without being separated into top and bottom, forexample. In this case, the separated columns 133 and continuous columnarregions 139 may be arrayed regularly (alternately, for example) or maybe arrayed randomly. As shown in FIG. 26, by selectively providing thecontinuous columnar regions 139 that are specialized for superjunctioncharacteristics, it is possible to adjust the trade-off between theswitching speed and on-resistance of the semiconductor device 151.

In the respective embodiments described above, the p-type columnarregions 103 were grown by multi-epitaxial growth, but the p-typecolumnar regions can be formed by forming deep trenches in the n⁻ baselayer 102 and then embedding the p-type semiconductor layers in thesedeep trenches, for example.

The structure of the cells 113 may be a planar gate structure as in therespective embodiments above, or may be a trench gate structure.

A configuration may be used in which the conductivity type of therespective semiconductor portions of the semiconductor devices 101, 141,and 151 are reversed. In the semiconductor device 101, the p-type partsmay be n-type and the n-type parts may be p-type, for example.

Besides these, various modifications in design can be made within thescope of the claims.

<Working Example>

FIG. 27 is a waveform diagram of one example of current waveform betweenthe source electrode 108 and the drain electrode 111 from when theparasitic diode 114 is in an ON-state to when it is turned OFF. As shownin FIG. 27, in the comparison example with the “Without SeparatedColumnar Region,” noise occurs due to ringing (vibration of the reverserecovery current) or sudden changes in the current when the parasiticdiode 114 is turned OFF. By contrast, in the working example with the“With Separated Columnar Region,” the reverse recovery current settlesback to zero smoothly and noise is suppressed.

<Simulation Example 3>

In Simulation Example 3, it was confirmed how the respectiveON-resistances in low voltage ranges and high voltage ranges changedepending on the presence or absence of the p⁺ collector layers 110 andthe presence or absence of the separated columns 133. The results areshown in FIGS. 28A and 28B. In FIGS. 28A and 28B, “4 cell pitch” meansthat the p⁺ collector layers 110 are provided at a pitch P₂ that is fourtimes (4 cell pitch) that of a pitch P₁ of the p-type columnar regions103 in the semiconductor device 141 shown in FIG. 20. The occupancy ofthe p⁺ collector layers 110=64%, and the ratio of width of the p⁺collector layers 110 to that of the n⁺ contact layer 109=1:1. Thesemiconductor device 141 has an IGBT structure due to a p-type siliconsubstrate being provided on the entire rear surface of the n⁻ base layer102.

According to FIG. 28A, if the separated column 133 is formed thenON-resistance is reduced in high voltage ranges as compared to if theseparated column 133 were not formed. The structural difference betweenthe “4 cell pitch (With Separated Columnar Region)” and “4 cell pitch”is that presence or absence of the separated columnar region. The “4cell pitch (With Separated Columnar Region)” allows more current to passthrough. In other words, the ON-resistance is reduced.

On the other hand, according to FIG. 28B, ON-resistance is reduced inthe low voltage ranges as compared to the IGBT structure due to thecontact between the n⁺ contact layer 109 and the drain electrode 111being left intact by selective forming of the p⁺ collector layers 110.

<Simulation Example 4>

In Simulation Example 4, it was confirmed how the parasitic outputcapacitance of the semiconductor device changes depending on the numberof separated columns 133. These results are shown in FIG. 29. In FIG.29, “With Continuous Column (For Every 2×Pitch)” means that every thirdp-type columnar region 103 serves as the continuous columnar region 139in the semiconductor device 151 shown in FIG. 26. In other words, thisis the configuration shown in FIG. 26. In this case, two separatedcolumns 133 are arranged between the adjacent continuous columnarregions 139. In a similar manner, “With Continuous Column (For Every4×Pitch)” means that every fifth p-type columnar region 103 serves asthe continuous columnar region 139, and “Without Continuous Column”means that all of the p-type columnar regions 103 are separated columns133.

According to FIG. 29, the parasitic output capacitance of thesemiconductor device is lowest in “Without Continuous Column,” secondlowest in “With Continuous Column (For Every 4×Pitch),” and highest in“With Continuous Column (For Every 2×Pitch)”. In other words, moreseparated columns 133 means a greater reduction in parasiticON-resistance.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the spirit or scope of the invention. Thus, it isintended that the present invention cover modifications and variationsthat come within the scope of the appended claims and their equivalents.In particular, it is explicitly contemplated that any part or whole ofany two or more of the embodiments and their modifications describedabove can be combined and regarded within the scope of the presentinvention.

The invention claimed is:
 1. A semiconductor device, comprising: a firstconductive type drain layer; a first conductive type drift layer formedon the first conductive type drain layer; a plurality of secondconductive type base layers selectively formed on a surface of the firstconductive type drift layer; a first conductive type source layer thatis formed in an inner area of the respective second conductive type baselayers at a gap from a periphery of the respective second conductivetype base layers, the first conductive type source layer forming achannel region with said periphery; a gate electrode formed so as toface the channel region across a gate insulating film; a secondconductive type columnar region that is formed in the first conductivetype drift layer and that extends towards the first conductive typedrain layer from at least some of the second conductive type baselayers; a drain electrode electrically connected to the first conductivetype drain layer; and a source electrode electrically connected to thefirst conductive type source layer, wherein the second conductive typecolumnar region has a top columnar region integrally formed with therespective second conductive type base layers and a bottom columnarregion that is electrically floating.
 2. The semiconductor deviceaccording to claim 1, further comprising: a second conductive typeauxiliary area formed at a location that is laterally separated with agap from both the top columnar region and the bottom columnar region. 3.The semiconductor device according to claim 1, wherein the top columnarregion and the bottom columnar region are separated by a gap that isless than or equal to 10μm in a vertical direction.
 4. The semiconductordevice according to claim 1, wherein at least some of the secondconductive type base layers selectively have a continuous columnarregion that continues from the respective second conductive type baselayers to a bottom edge of the bottom columnar region.
 5. Thesemiconductor device according to claim 1, further comprising: a secondconductive type collector layer partially formed on a rear surface ofthe first conductive type drain layer.
 6. The semiconductor deviceaccording to claim 5, wherein the second conductive type columnar regionis arranged at a prescribed first pitch between the second conductivetype base layers that are adjacent, and wherein the second conductivetype collector layer is arranged at a prescribed second pitch largerthan the first pitch of the second conductive type columnar region. 7.The semiconductor device according to claim 6, wherein the occupancy ofthe second conductive type collector layer with respect to the entirerear surface of the first conductive type drain layer is 40% to 80%. 8.A method of manufacturing a semiconductor device, comprising: forming afirst conductive type drift layer on a first conductive type drain layerby selectively implanting a second conductive type impurity into aprescribed first horizontal location and then forming a bottom mainlayer that is of a first conductive type through epitaxial growth for afirst period of time in locations other than said prescribed firsthorizontal location, thereafter forming a first conductive typesub-layer through epitaxial growth on the entirety of said bottom mainlayer, and then forming thereon a top main layer having the samestructure as the bottom main layer through epitaxial growth for a secondperiod of time that is shorter than the first period of time; forming asecond conductive type columnar region by annealing the first conductivetype drift layer having the top main layer and the bottom main layer andthen diffusing the second conductive type impurity inside the top mainlayer and the bottom main layer, the second conductive type columnarregion having a top columnar region vertically separated by thesub-layer and a bottom columnar region; selectively forming a secondconductive type base layer on the surface of the first conductive typedrift layer, the second conductive type base layer continuing from thesecond conductive type columnar region; forming a first conductive typesource layer on an inner area of the second conductive type base layersuch that a gap is present between a periphery of the second conductivetype base layer and the first conductive type source region, the firstconductive type source layer forming a channel region between saidperiphery and the second conductive type base layer; forming a gateelectrode so as to face the channel region across a gate insulatingfilm; forming a drain electrode that is electrically connected to thefirst conductive type drain layer; and forming a source electrode thatis electrically connected to the first conductive type source layer. 9.The method of manufacturing a semiconductor device according to claim 8,wherein the step of forming the first conductive type drift layerincludes forming the bottom main layer by epitaxially growing aplurality of layers at a prescribed first thickness, thereafterepitaxially growing a single layer of the sub-layer having the samethickness as the first prescribed thickness, and then forming the topmain layer by again epitaxially growing a plurality of the layers havingthe first prescribed thickness but in a smaller number than the bottommain layer.
 10. The method of manufacturing a semiconductor deviceaccording to claim 8, wherein forming the sub-layer through epitaxialgrowth in the step of forming a first conductive type drift layerincludes forming the sub-layer while implanting the second conductivetype impurity at a second horizontal location that is laterallyseparated from the first horizontal location, and wherein the step offorming the second conductive type columnar region includes forming thesecond conductive type auxiliary area with gaps from both the topcolumnar region and the bottom columnar region by diffusing the secondconductive type impurity inside the sub-layer through the annealingtreatment.
 11. The method of manufacturing a semiconductor deviceaccording to claim 8, wherein forming the sub-layer through epitaxialgrowth in the step of forming a first conductive type drift layerincludes forming a buffer layer of 5μm to 30μm.